Compositions of interpolymers of alpha-olefin monomers with one or more vinyl or vinylidene aromatic monomers and/or one or more hindered aliphatic or cycloaliphatic vinyl or vinylidene monomers blended with a conductive additive

ABSTRACT

A blend of polymeric materials comprising  
     (A) of from about 1 to about 99.99 weight percent based on the combined weights of Components A, B and C of at least one substantially random interpolymer; and wherein said interpolymer;  
     (1) contains of from about 0.5 to about 65 mole percent of polymer units derived from;  
     (a) at least one vinyl or vinylidene aromatic monomer, or  
     (b) at least one hindered aliphatic or cycloaliphatic vinyl or vinylidene monomer, or  
     (c) a combination of at least one vinyl or vinylidene aromatic monomer and at least one hindered aliphatic or cycloaliphatic vinyl or vinylidene monomer;  
     (2) contains of from about 35 to about 99.5 mole percent of polymer units derived from at least one aliphatic α-olefin having from 2 to 20 carbon atoms;  
     (3) has a molecular weight (Mn) greater than about 1,000;  
     (4) has a melt index (I 2 ) of from about 0.01 to about 1,000;  
     (5) has a molecular weight distribution (M w /M n ) of from about 1.5 to about 20; and  
     (B) of from about 99 to about 0.01 weight percent based on the combined weights of Components A, B, and C of one or more conductive additives and/or one or more additives with high magnetic permeability; and  
     (C) of from 0 to about 98.99 weight percent based on the combined weights of Components A, B, and C of one or more polymers other than A.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. ProvisionalApplication No. 60/062,305 filed Oct. 17, 1997.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable.

BACKGROUND OF THE INVENTION

[0003] This invention relates to compositions of interpolymers ofα-olefin monomers with one or more vinyl or vinylidene aromatic monomersand/or one or more hindered aliphatic or cycloaliphatic vinyl orvinylidene monomers blended with one or more conductive additives and,optionally one or more additional polymers.

[0004] The generic class of materials of α-olefin/vinyl or vinylidenemonomer substantially random interpolymers, (including interpolymers ofα-olefin/vinyl aromatic monomers) and their preparation, are known inthe art, and are described in EP 416 815 A2.

[0005] The structure, thermal transitions and mechanical properties ofsubstantially random interpolymers of ethylene and styrene containing upto about 50 mole percent styrene have been described (Y. W. Cheung, M.J. Guest; Proc. Antec '96 pages 1634-1637). The interpolymers were foundto have glass transitions in the range −20° C. to ±35° C., and had nomeasurable crystallinity above about 25 mole percent styreneincorporation, i.e. they are essentially amorphous.

[0006] Materials such as substantially random ethylene/styreneinterpolymers offer a wide range of material structures and propertieswhich makes them useful for varied applications, such as asphaltmodifiers or as compatibilizers for blends of polyethylene andpolystyrene (as described in U.S. Pat. No. 5,460,818.) Although ofutility in their own right, industry is constantly seeking to improvethe applicability of these interpolymers. To perform well in certainapplications, these interpolymers could be desirably improved, forexample, in the areas of electrical conductivity and/or magneticpermeability.

[0007] The ability to impart either electrical conductivity or magneticpermeability to materials can be an important factor in a number ofapplications. For instance the property attribute of semiconductivity(about 10⁻⁹ to 10⁻² S/cm) in a material enhances its use in applicationswhich require electrostatic painting, electronics manufacturing andshipping, conductive fibers for antistatic carpet and clothing,antistatic flooring, and also for semiconductive films. Higher levels ofconductivity are also required in applications such as cable shielding,resettable fuses, EMI shielding, and direct electroplating ontoplastics. In general, the key issues for conductive modification ofexisting materials are the maintenance of acceptable properties in thehost material and minimization of the amount of conductive additiverequired to add the conductivity which can also be an issue for cost.

[0008] Magnetic permeability is a desirable feature in applications suchas electromagnetic wave attenuation, that is, shielding of electricalequipment and circuits in numerous electrical devices from thedeleterious effects of electromagnetic interference (EMI) present in theenvironment. EMI shielding is also important in containing the EMIwithin the EMI generating source as dictated by the specifications forelectrical equipment imposed by both Government and private industry.

[0009] We have now found that interpolymers of α-olefin monomers withone or more vinyl or vinylidene aromatic monomers and/or one or morehindered aliphatic or cycloaliphatic vinyl or vinylidene monomers becomesemielectrically conductive (about 10⁻⁹ to 10⁻² S/cm) by melt orsolution blending low loadings of a conductive additive such asconductive carbon. We have also found that such interpolymers becomesignificantly conductive (>0.01 S/cm) when larger amounts of conductiveadditives are incorporated.

[0010] We have also found that the combination of relatively smallamounts of interpolymers of α-olefin monomers with one or more vinyl orvinylidene aromatic monomers and/or one or more hindered aliphatic orcycloaliphatic vinyl or vinylidene monomers, a conductive additive, andan additional polymer can enhance the conductivity of the blend incomparison to the cases where there is no interpolymer, when all otherfactors such as conductive additive level and processing parameters areheld constant.

[0011] We have also found that this enhancement can bring theconductivity to the surface of the composite under conditions which mayotherwise yield an insulating surface.

[0012] Finally, we have found that the use of two or more interpolymersof α-olefin monomers with one or more vinyl or vinylidene aromaticmonomers and/or one or more hindered aliphatic or cycloaliphatic vinylor vinylidene monomers which have differing vinyl or vinylidene monomercontents can also significantly enhance the conductivity both at thesurface and throughout the bulk of the composite.

[0013] In yet another aspect of the present invention, the interpolymersof α-olefin monomers with one or more vinyl or vinylidene aromaticmonomers and/or one or more hindered aliphatic or cycloaliphatic vinylor vinylidene monomers can be mixed with intrinsically conductivepolymers (ICP) such as certain appropriately doped polyanilines, toproduce a relatively optically transmissive films having antistaticproperties when, for example, cast from solution. Certain appropriatelydoped polyanilines (as described for instance in copending ProvisionalU.S. Application filed on Oct. 15, 1997 entitled“Electrically-Conductive Polymers” by Susan J. Babinec et al., andherein incorporated by reference) appear to be miscible with theinterpolymers of α-olefin monomers with one or more vinyl or vinylidenearomatic monomers and/or one or more hindered aliphatic orcycloaliphatic vinyl or vinylidene monomers. These mixtures can producea clear, rather than cloudy or opaque, film as a result of goodmiscibility such that discreet particles are not seen under a lightmicroscope at magnifications as high as 500×. Such effectivelytransparent films which are semiconductive and do not contain discreetparticles are a much desired product, for example, for antistaticapplications related to electronics manufacturing and shipping. Themiscibility of certain polyanilines in the interpolymers of α-olefinmonomers with one or more vinyl or vinylidene aromatic monomers and/orone or more hindered aliphatic or cycloaliphatic vinyl or vinylidenemonomers is also an important feature in processes such as blowingfoams, and films where fine microstructure is also critical.

BRIEF SUMMARY OF THE INVENTION

[0014] This invention relates to blends of polymeric materialscomprising

[0015] (A) of from about 1 to about 99.99 weight percent based on thecombined weights of Components A, B and C of at least one substantiallyrandom interpolymer; and wherein said interpolymer;

[0016] (1) contains of from about 0.5 to about 65 mole percent ofpolymer units derived from;

[0017] (a) at least one vinyl or vinylidene aromatic monomer, or

[0018] (b) at least one hindered aliphatic or cycloaliphatic vinyl orvinylidene monomer, or

[0019] (c) a combination of at least one vinyl or vinylidene aromaticmonomer and at least one hindered aliphatic or cycloaliphatic vinyl orvinylidene monomer;

[0020] (2) contains of from about 35 to about 99.5 mole percent ofpolymer units derived from at least one aliphatic α-olefin having from 2to 20 carbon atoms;

[0021] (3) has a molecular weight (Mn) greater than about 1,000;

[0022] (4) has a melt index (I₂) of from about 0.01 to about 1,000;

[0023] (5) has a molecular weight distribution (M_(w)/M_(n)) of fromabout 1.5 to about 20; and

[0024] (B) of from about 99 to about 0.01 weight percent based on thecombined weights of Components A, B, and C of one or more conductiveadditives and/or one or more additives with high magnetic permeability;and

[0025] (C) of from 0 to about 98.99 weight percent based on the combinedweights of Components A, B, and C of one or more polymers other than A.

BRIEF DESCRIPTION OF DRAWINGS

[0026]FIG. 1 is an illustration of the method of determining SurfaceConductivity.

[0027]FIG. 2 is an illustration of the method of determining CoreConductivity.

DETAILED DESCRIPTION OF THE INVENTION Definitions

[0028] All references herein to elements or metals belonging to acertain Group refer to the Periodic Table of the Elements published andcopyrighted by CRC Press, Inc., 1989. Also any reference to the Group orGroups shall be to the Group or Groups as reflected in this PeriodicTable of the Elements using the IUPAC system for numbering groups.

[0029] Any numerical values recited herein include all values from thelower value to the upper value in increments of one unit provided thatthere is a separation of at least 2 units between any lower value andany higher value. As an example, if it is stated that the amount of acomponent or a value of a process variable such as, for example,temperature, pressure, time and the like is, for example, from 1 to 90,preferably from 20 to 80, more preferably from 30 to 70, it is intendedthat values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. areexpressly enumerated in this specification. For values which are lessthan one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 asappropriate. These are only examples of what is specifically intendedand all possible combinations of numerical values between the lowestvalue and the highest value enumerated are to be considered to beexpressly stated in this application in a similar manner.

[0030] The term “hydrocarbyl” as employed herein means any aliphatic,cycloaliphatic, aromatic, aryl substituted aliphatic, aryl substitutedcycloaliphatic, aliphatic substituted aromatic, or aliphatic substitutedcycloaliphatic groups.

[0031] The term “hydrocarbyloxy” means a hydrocarbyl group having anoxygen linkage between it and the carbon atom to which it is attached.

[0032] The term “copolymer” as employed herein means a polymer whereinat least two different monomers are polymerized to form the copolymer.

[0033] The term “interpolymer” is used herein to indicate a polymerwherein at least two different monomers are polymerized to make theinterpolymer. This includes copolymers, terpolymers, etc.

[0034] The term “substantially random” in the substantially randominterpolymer comprising an α-olefin and a vinyl or vinylidene aromaticmonomer or hindered aliphatic or cycloaliphatic vinyl or vinylidenemonomer as used herein means that the distribution of the monomers ofsaid interpolymer can be described by the Bernoulli statistical model orby a first or second order Markovian statistical model, as described byJ. C. Randall in POLYMER SEQUENCE DETERMINATION, Carbon-13 NMR Method,Academic Press New York, 1977, pp. 71-78. Preferably, the substantiallyrandom interpolymer comprising an α-olefin and a vinyl or vinylidenearomatic monomer does not contain more than 15 percent of the totalamount of vinyl or vinylidene aromatic monomer in blocks of vinyl orvinylidene aromatic monomer of more than 3 units. More preferably, theinterpolymer was not characterized by a high degree of eitherisotacticity or syndiotacticity. This means that in the carbon⁻¹³ NMRspectrum of the substantially random interpolymer the peak areascorresponding to the main chain methylene and methine carbonsrepresenting either meso diad sequences or racemic diad sequences shouldnot exceed 75 percent of the total peak area of the main chain methyleneand methine carbons.

[0035] The Substantially Random Ethylene/Vinyl or VinylideneInterpolymers

[0036] The substantially random interpolymer blend components of thepresent invention include interpolymers prepared by polymerizing one ormore α-olefins with one or more vinyl or vinylidene aromatic monomersand/or one or more hindered aliphatic or cycloaliphatic vinyl orvinylidene monomers.

[0037] Suitable α-olefins include for example, α-olefins containing from2 to about 20, preferably from 2 to about 12, more preferably from 2 toabout 8 carbon atoms. Particularly suitable are ethylene, propylene,butene-1,4-methyl-1-pentene, hexene-1 and octene-1. These α-olefins donot contain an aromatic moiety. Preferred are ethylene in combinationwith a C₃-C₈ α-olefin, more preferred is ethylene.

[0038] Other optional polymerizable ethylenically unsaturated monomer(s)include norbornene and C₁₋₁₀ alkyl or C₆₋₁₀ aryl substitutednorbornenes, with an exemplary interpolymer beingethylene/styrene/norbornene.

[0039] Suitable vinyl or vinylidene aromatic monomers which can beemployed to prepare the interpolymers include, for example, thoserepresented by the following formula:

[0040] wherein R¹ is selected from the group of radicals consisting ofhydrogen and alkyl radicals containing from 1 to about 4 carbon atoms,preferably hydrogen or methyl; each R² is independently selected fromthe group of radicals consisting of hydrogen and alkyl radicalscontaining from 1 to about 4 carbon atoms, preferably hydrogen ormethyl; Ar is a phenyl group or a phenyl group substituted with from 1to 5 substituents selected from the group consisting of halo,C₁₋₄-alkyl, and C₁₋₄-haloalkyl; and n has a value from zero to about 4,preferably from zero to 2, most preferably zero.

[0041] Exemplary vinyl aromatic monomers include styrene, vinyl toluene,α-methylstyrene, t-butyl styrene, chlorostyrene, including all isomersof these compounds, and the like. Particularly suitable such monomersinclude styrene and lower alkyl- or halogen-substituted derivativesthereof. Preferred monomers include styrene, α-methyl styrene, the loweralkyl- (C₁-C₄) or phenyl-ring substituted derivatives of styrene, suchas for example, ortho-, meta-, and para-methylstyrene, the ringhalogenated styrenes, para-vinyl toluene or mixtures thereof, and thelike. A more preferred aromatic vinyl monomer is styrene.

[0042] By the term “hindered aliphatic or cycloaliphatic vinyl orvinylidene compounds”, it is meant addition polymerizable vinyl orvinylidene monomers corresponding to the formula:

[0043] wherein A¹ is a sterically bulky, aliphatic or cycloaliphaticsubstituent of up to 20 carbons, R¹ is selected from the group ofradicals consisting of hydrogen and alkyl radicals containing from 1 toabout 4 carbon atoms, preferably hydrogen or methyl; each R² isindependently selected from the group of radicals consisting of hydrogenand alkyl radicals containing from 1 to about 4 carbon atoms, preferablyhydrogen or methyl; or alternatively R¹ and A¹ together form a ringsystem. By the term “sterically bulky” is meant that the monomer bearingthis substituent is normally incapable of addition polymerization bystandard Ziegler-Natta polymerization catalysts at a rate comparablewith ethylene polymerizations. However, simple linear α-olefinsincluding for example, α-olefins containing from 3 to about 20 carbonatoms such as ethylene, propylene, butene-1,4-methyl-1-pentene, hexene-1or octene-1 are not examples of sterically hindered aliphatic orcycloaliphatic vinyl or vinylidene compounds.

[0044] Preferred hindered aliphatic or cycloaliphatic vinyl orvinylidene compounds are monomers in which one of the carbon atomsbearing ethylenic unsaturation is tertiary or quaternary substituted.Examples of such substituents include cyclic aliphatic groups such ascyclohexyl, cyclohexenyl, cyclooctenyl, or ring alkyl or arylsubstituted derivatives thereof, tert-butyl, norbornyl, and the like.Most preferred hindered aliphatic or cycloaliphatic vinyl or vinylidenecompounds are the various isomeric vinyl-ring substituted derivatives ofcyclohexene and substituted cyclohexenes, and 5-ethylidene-2-norbornene.Especially suitable are 1-, 3-, and 4-vinylcyclohexene.

[0045] The substantially random interpolymers may be modified by typicalgrafting, hydrogenation, functionalizing, or other reactions well knownto those skilled in the art. The polymers may be readily sulfonated orchlorinated to provide functionalized derivatives according toestablished techniques. The substantially random interpolymers may alsobe modified by various chain extending or cross-linking processesincluding, but not limited to peroxide-, silane-, sulfur-, radiation-,or azide-based cure systems. A full description of the variouscross-linking technologies is described in copending U.S. patentapplication Nos. 08/921,641 and 08/921,642 both filed on Aug. 27, 1997,the entire contents of both of which are herein incorporated byreference. Dual cure systems, which use a combination of heat, moisturecure, and radiation steps, may be effectively employed. Dual curesystems are disclosed and claimed in U.S. patent application Ser. No.536,022, filed on Sep. 29, 1995, in the names of K. L. Walton and S. V.Karande, incorporated herein by reference. For instance, it may bedesirable to employ peroxide crosslinking agents in conjunction withsilane crosslinking agents, peroxide crosslinking agents in conjunctionwith radiation, sulfur-containing crosslinking agents in conjunctionwith silane crosslinking agents, etc. The substantially randominterpolymers may also be modified by various cross-linking processesincluding, but not limited to the incorporation of a diene component asa termonomer in its preparation and subsequent cross linking by theaforementioned methods and further methods including vulcanization viathe vinyl group using sulfur for example as the cross linking agent.

[0046] One method of preparation of the substantially randominterpolymers includes polymerizing a mixture of polymerizable monomersin the presence of one or more metallocene or constrained geometrycatalysts in combination with various cocatalysts, as described inEP-A-0,416,815 by James C. Stevens et al. and U.S. Pat. No. 5,703,187 byFrancis J. Timmers, both of which are incorporated herein by referencein their entirety. Preferred operating conditions for suchpolymerization reactions are pressures from atmospheric up to 3000atmospheres and temperatures from −30° C. to 200° C. Polymerizations andunreacted monomer removal at temperatures above the autopolymerizationtemperature of the respective monomers may result in formation of someamounts of homopolymer polymerization products resulting from freeradical polymerization.

[0047] Examples of suitable catalysts and methods for preparing thesubstantially random interpolymers are disclosed in U.S. applicationSer. No. 702,475, filed May 20, 1991 (EP-A-514,828); as well as U.S.Pat. Nos.: 5,055,438; 5,057,475; 5,096,867; 5,064,802; 5,132,380;5,189,192; 5,321,106; 5,347,024; 5,350,723; 5,374,696; 5,399,635;5,470,993; 5,703,187; and 5,721,185 all of which patents andapplications are incorporated herein by reference.

[0048] The substantially random α-olefin/vinyl or vinylidene aromaticinterpolymers can also be prepared by the methods described in JP07/278230 employing compounds shown by the general formula

[0049] where Cp¹ and Cp² are cyclopentadienyl groups, indenyl groups,fluorenyl groups, or substituents of these, independently of each other;R¹ and R² are hydrogen atoms, halogen atoms, hydrocarbon groups withcarbon numbers of 1-12, alkoxy groups, or aryloxy groups, independentlyof each other; M is a group IV metal, preferably Zr or Hf, mostpreferably Zr; and R³ is an alkylene group or silanediyl group used tocross-link Cp¹ and Cp².

[0050] The substantially random α-olefin/vinyl or vinylidene aromaticinterpolymers can also be prepared by the methods described by John G.Bradfute et al. (W.R. Grace & Co.) in WO 95/32095; by R. B. Pannell(Exxon Chemical Patents, Inc.) in WO 94/00500; and in PlasticsTechnology, p. 25 (September 1992), all of which are incorporated hereinby reference in their entirety.

[0051] Also suitable are the substantially random interpolymers whichcomprise at least one α-olefin/vinyl aromatic/vinyl aromatic/α-olefintetrad disclosed in U.S. application No. 08/708,869 filed Sep. 4, 1996by Francis J. Timmers et al. These interpolymers contain additionalsignals with intensities greater than three times the peak to peaknoise. These signals appear in the chemical shift range 43.70-44.25 ppmand 38.0-38.5 ppm. Specifically, major peaks are observed at 44.1, 43.9and 38.2 ppm. A proton test NMR experiment indicates that the signals inthe chemical shift region 43.70-44.25 ppm are methine carbons and thesignals in the region 38.0-38.5 ppm are methylene carbons.

[0052] It is believed that these new signals are due to sequencesinvolving two head-to-tail vinyl aromatic monomer insertions precededand followed by at least one α-olefin insertion, e.g. anethylene/styrene/styrene/ethylene tetrad wherein the styrene monomerinsertions of said tetrads occur exclusively in a 1,2 (head to tail)manner. It is understood by one skilled in the art that for such tetradsinvolving a vinyl aromatic monomer other than styrene and an α-olefinother than ethylene that the ethylene/vinyl aromatic monomer/vinylaromatic monomer/ethylene tetrad will give rise to similar carbon⁻¹³ NMRpeaks but with slightly different chemical shifts.

[0053] These interpolymers are prepared by polymerizing at temperaturesof from about −30° C. to about 250° C. in the presence of such catalystsas those represented by the formula

[0054] wherein: each Cp is independently, each occurrence, a substitutedcyclopentadienyl group π-bound to M; E is C or Si; M is a group IVmetal, preferably Zr or Hf, most preferably Zr; each R is independently,each occurrence, H, hydrocarbyl, silahydrocarbyl, or hydrocarbylsilyl,containing up to about 30 preferably from 1 to about 20 more preferablyfrom 1 to about 10 carbon or silicon atoms; each R¹ is independently,each occurrence, H, halo, hydrocarbyl, hydrocarbyloxy, silahydrocarbyl,hydrocarbylsilyl containing up to about 30 preferably from 1 to about 20more preferably from 1 to about 10 carbon or silicon atoms or two R′groups together can be a C₁₋₁₀ hydrocarbyl substituted 1,3-butadiene; mis 1 or 2; and optionally, but preferably in the presence of anactivating cocatalyst, particularly, suitable substitutedcyclopentadienyl groups include those illustrated by the formula:

[0055] wherein each R is independently, each occurrence, H, hydrocarbyl,silahydrocarbyl, or hydrocarbylsilyl, containing up to about 30preferably from 1 to about 20 more preferably from 1 to about 10 carbonor silicon atoms or two R groups together form a divalent derivative ofsuch group. Preferably, R independently each occurrence is (includingwhere appropriate all isomers) hydrogen, methyl, ethyl, propyl, butyl,pentyl, hexyl, benzyl, phenyl or silyl or (where appropriate) two such Rgroups are linked together forming a fused ring system such as indenyl,fluorenyl, tetrahydroindenyl, tetrahydrofluorenyl, oroctahydrofluorenyl.

[0056] Particularly preferred catalysts include, for example,racemic-(dimethylsilanediyl)-bis-(2-methyl-4-phenylindenyl) zirconiumdichloride, racemic-(dimethylsilanediyl)-bis-(2-methyl-4-phenylindenyl)zirconium 1,4-diphenyl-1,3-butadiene,racemic-(dimethylsilanediyl)-bis-(2-methyl-4-phenylindenyl) zirconiumdi-C1-4 alkyl,racemic-(dimethylsilanediyl)-bis-(2-methyl-4-phenylindenyl) zirconiumdi-C1-4 alkoxide, or any combination thereof and the like.

[0057] It is also possible to use the following titanium-basedconstrained geometry catalysts,[N-(1,1-dimethylethyl)-1,1-dimethyl-1-[(1,2,3,4,5-η)-1,5,6,7-tetrahydro-s-indacen-1-yl]silanaminato(2-)-N]titaniumdimethyl; (1-indenyl)(tert-butylamido)dimethyl-silane titanium dimethyl;((3-tert-butyl)(1,2,3,4,5-η)-1-indenyl)(tert-butylamido) dimethylsilanetitanium dimethyl; and((3-iso-propyl)(1,2,3,4,5-η)-1-indenyl)(tert-butyl amido)dimethylsilanetitanium dimethyl, or any combination thereof and the like.

[0058] Further preparative methods for the substantially randomα-olefin/vinylidene aromatic interpolymers blend components of thepresent invention have been described in the literature. Longo andGrassi (Makromol. Chem., Volume 191, pages 2387 to 2396[1990]) andD'Anniello et al. (Journal of Applied Polymer Science, Volume 58, pages1701-1706[1995]) reported the use of acatalytic system based onmethylalumoxane (MAO) and cyclopentadienyltitanium trichloride (CpTiCl₃)to prepare an ethylene-styrene copolymer. Xu and Lin (Polymer Preprints,Am. Chem. Soc. Div. Polym. Chem.) Volume 35, pages 686, 687[1994]) havereported copolymerization using a MgCl₂/TiCl₄/NdCl₃/Al(iBu)₃ catalyst togive random copolymers of styrene and propylene. Lu et al (Journal ofApplied Polymer Science, Volume 53, pages 1453 to 1460[1994]) havedescribed the copolymerization of ethylene and styrene using aTiCl₄/NdCl₃/MgCl₂/Al(Et)₃ catalyst. The manufacture of α-olefin/vinylaromatic monomer interpolymers such as propylene/styrene andbutene/styrene are described in U.S. Pat. No. 5,244,996, issued toMitsui Petrochemical Industries Ltd. or U.S. Pat. No. 5,652,315 alsoissued to Mitsui Petrochemical Industries Ltd or as disclosed in DE 19711 339 A1 to Denki Kagaku Kogyo KK. All the above methods disclosed forpreparing the interpolymer component are incorporated herein byreference.

[0059] Also included as interpolymer blend components are C₄-C₇,isoolefin/para alkylstyrene interpolymers which are random copolymers ofa C₄ to C₇ isomonoolefin, such as isobutylene and a para alkylstyrenecomonomer, preferably para methylstyrene containing at least about 80%,more preferably at least about 90% by weight of the para isomer. Theseinterpolymers also include functionalized interpolymers wherein at leastsome of the alkyl substituent groups present in the styrene monomerunits contain halogen or some other functional group incorporated bynucleophilic substitution of benzylic halogen with other groups such asalkoxide, phenoxide, carboxylate, thiolate, thioether, thiocarbamate,dithiocarbamate, thiourea, xanthate, cyanide, malonate, amine, amide,carbazole, phthalamide, maleimide, cyanate and mixtures thereof.

[0060] Preferred materials may be characterized as isobutyleneinterpolymers containing the following monomer units randomly spacedalong the polymer chain: These functionalized isomonoolefininterpolymers and their method of preparation are more particularlydisclosed in U.S. Pat. No. 5,162,445, the complete disclosure of whichis incorporated herein by reference.

[0061] Most useful of such functionalized materials are elastomeric,random interpolymers of isobutylene and para methylstyrene containingfrom about 0.5 to about 20 mole % para methylstyrene wherein up to about60 mole % of the methyl substituent groups present on the benzyl ringcontain a bromine or chlorine atom, preferably a bromine atom. Thesepolymers have a substantially homogeneous compositional distributionsuch that at least 95% by weight of the polymer has a para alkylstyrenecontent within 10% of the average para alkylstyrene content of thepolymer. More preferred polymers are also characterized by a narrowmolecular weight distribution (M_(w)/M_(n)) of less than about 5, morepreferably less than about 2.5. The preferred viscosity averagemolecular weight is in the range of from about 200,000 up to about2,000,000, and the preferred number average molecular weight is in therange of from about 25,000 to about 750,000, as determined by GelPermeation Chromatography.

[0062] The interpolymers may be prepared by slurry polymerization of themonomer mixture using a Lewis Acid catalyst followed by halogenation,preferably bromination, in solution in the presence of halogen and aradical initiator such as heat and/or light and/or a chemical initiator.

[0063] Preferred interpolymers are brominated interpolymers whichgenerally contain from about 0.1 to about 5 mole % of bromomethylgroups,most of which is monobromomethyl, with less than 0.05 mole %dibromomethyl substituents present in the copolymer. More preferredinterpolymers contain from about 0.05 up to about 2.5 wt % of brominebased on the weight of the interpolymer, most preferably from about 0.05to 0.75 wt % bromine, and are substantially free of ring halogen orhalogen in the polymer backbone chain. These interpolymers, their methodof preparation, their method of cure and graft or functionalizedpolymers derived therefrom are more particularly disclosed in the abovereferenced U.S. Pat. No.5,162,445. Such interpolymers are commerciallyavailable from Exxon Chemical under the tradename Exxpro™ SpecialityElastomers.

[0064] Crosslinked Interpolymers

[0065] One or more dienes can optionally be incorporated into theinterpolymer to provide functional sites of unsaturation on theinterpolymer which are useful, for example, to participate incrosslinking reactions. While conjugated dienes such as butadiene,1,3-pentadiene (that is, piperylene), or isoprene may be used for thispurpose, nonconjugated dienes are preferred. Typical nonconjugateddienes include, for example the open-chain nonconjugated diolefins suchas 1,4-hexadiene (see U.S. Pat. No. 2,933,480) and7-methyl-1,6-octadiene (also known as MOCD); cyclic dienes; bridged ringcyclic dienes, such as dicyclopentadiene (see U.S. Pat. No. 3,211,709);or alkylidenenorbornenes, such as methylenenorbornene orethylidenenorbornene (see U.S. Pat. No. 3,151,173). The nonconjugateddienes are not limited to those having only two double bonds, but ratheralso include those having three or more double bonds.

[0066] The diene is incorporated in the interpolymers of the inventionin an amount of from 0 to 15 weight percent based on the total weight ofthe interpolymer. When a diene is employed, it will preferably beprovided in an amount of at least 2 weight percent, more preferably atleast 3 weight percent, and most preferably at least 5 weight percent,based on the total weight of the interpolymer. Likewise, when a diene isemployed, it will be provided in an amount of no more than 15,preferably no more than 12 weight percent based on the total weight ofthe interpolymer.

[0067] Conductive Additive

[0068] Conductive additives can differ by various parameters includingchemical nature, particle shape e.g. fiber strand vs. spherical particlevs. flat platelet, particle size and size distribution, specific surfacearea, surface tension, color, optical density in the visible spectrum,degree of electrical conductivity, glass transition temperature (T_(g)),thermal stability, solubility, chemical reactivity, environmentalstability, density and bulk density, and hydrophilicity.

[0069] For conductive blend compositions, important blend propertieswhich need to be balanced are; conductivity, meltrheology/dispersability (for processability), impact properties,mechanical strength, water adsorption, homogeneity, cost, dielectricstrength, gloss, aesthetics, abrasion and wear resistance, glasstransition temperature range, filler adhesion to the matrix. Inaddition, for semiconducting blend compositions important propertieswill also include optical transmissivity, chemical resistance,insensitivity to changes in relative humidity. Any particular balance ofblend properties will depend upon the specific end-use application, andwill, in part, dictate the choice of conductive additive.

[0070] 1) Electrically Conductive Additives

[0071] a) Conductive Carbon Blacks

[0072] The electrically conductive additives include but are not limitedto all the known types of conductive carbon blacks. There are a widevariety of carbon blacks which all have a certain level of conductivity,produced industrially and otherwise, by a variety of differentprocesses. However, the “conductive carbons” referred to in this textare those which allow good development of conductivity when blended intocertain binders. Typically, the conductive carbon blacks have a high orvery high level of structure as measured by several tests. Primaryparticle size and carbon microstructure is evaluated with a transmissionelectron micrograph (TEM). Carbon blacks having high structure tend toshow distinct linkages and a low number of isolated aggregates under TEMobservation. Additionally, oil absorption used in accordance to ASTM D2314 provides numerical values of the interstitial cavity volume. Carbonblacks which are considered conductive for the purposes described hereinare those having relatively high oil absorption, typically greater than500%, preferably greater than 400%.

[0073] Aggregation is another parameter which is related to carbonstructure, and is estimated according to dibutyl phthalate (DBP)adsorption. Conductive carbon blacks which are useful for the purposesof this invention are those including but not limited to carbon blackshaving a DBP adsorption value greater than about 100 ml/100 g,preferably greater than about 70 ml/100 g. Tapped density (DIN ISO787/11) also estimates the degree of structure. Conductive carbons, forthe purposes of this invention, include but are not limited to thosehaving a tapped density of less than about 500 g/l. Another veryimportant value is the proportion of polar groups on the surface of thecarbon. Polar groups reduce the electrical conductivity. The level ofpolar surface groups is a parameter which is easily determined as thepercent volatiles, and is measured according to ASTM D 1620. Conductivecarbon blacks useful for this invention include but are not limited tothose having less than 2 wt. % volatiles. Conductivity is also relatedto the level of contaminants (for example ash, sulfur, varioustransition metals and the like) in the conductive carbon, and theirconcentration generally needs to be less than 20 ppm in carbon blackshaving good conductivity.

[0074] It is also well known in the art that the details of melt andsolution processing can significantly effect the conductivity of apolymer or polymer blend with a conductive additive. These effects areespecially significant for the dispersion of conductive carbon blacksinto a polymer since the conductive carbon black structure decreasesnearly continuously with the total shear energy deposited into thesystem during blending, and since the conductivity requires contactbetween conductive additive materials. Additionally, some conductivecarbon blacks can be surface-treated for improved dispersion. Forpurposes of these teachings it is understood that comparisons betweensamples are made under processing conditions which approximate nearlyequivalent total shear energy in the blended system. Similarly, it isknown that cooling kinetics can affect conductivity of the composites.

[0075] b) Intrinsically-Conductive Polymers (ICP)

[0076] Also included as an electronically conductive additive in thecompositions of the present invention are the doped and undopedconjugated intrinsically electrically conductive oriented or unoriented,amorphous and semicrystalline polymers such as substituted andunsubstituted polyanilines, polyacetylenes, polypyrroles, poly(phenylenesulfides), polyindoles, polythiophenes and poly(alkyl) thiophenes,polyphenylenes, polyvinylene/phenylenes, and their copolymers such asrandom or block copolymers of for example, acetylenes and thiophenes oranilines and thiophenes. Also included are derivatives thereof such aspoly(N-methyl)pyrrole, poly(o-ethoxy)aniline, polyethylenedioxythiophene (PEDT), and poly (3-octyl)thiophene.

[0077] These materials are called “intrinsically-conductive polymers” or“ICP” and as used herein refers to a polymer with extended pi-conjugatedgroups which may be rendered conductive with a dopant such as a Lewis orLowry-Bronsted acid or a redox agent to form a charge transfer complexwith a conductivity of at least about 10⁻¹² S/cm. The charge transfermay be full or partial, depending on the specific electrondonor/electron acceptor pair. For example, partial charge transferbetween certain lithium salts and polyaniline has been found to increasethe conductivity of the polyaniline. Full charge transfer is believed tooccur with polyaniline and protons, and polythiophene and protons ortransition metals. The process of rendering the polymer electronicallyconductive is referred to herein as “doping”. ICPs which have beenrendered conductive and have not been rendered conductive are referredto herein as “doped” ICPs and “undoped” ICPs, respectively. Thecompounds and polymers which may be used in such doping processes torender the ICPs conductive are referred to herein as “dopants”.

[0078] When low cost and high temperature stability are important theICP is preferably a polyaniline, polypyrrole, or polythiophene, but ismost preferably a polyaniline. However, if the ICP is used to prepare acomposite with a thermoplastic or thermoset polymer, the choice of ICPmay also depend on its compatibility with such polymer. For example,polypyrrole is especially compatible with polymers with which it canform hydrogen bonds along its backbone; polyalkylthiophenes areparticularly compatible with polyolefins and polystyrene; andpolyacetylenes are particularly compatible with polyolefins.

[0079] Polyaniline can occur in several different oxidative states suchas leucoemeraldine, protoemeraldine, emeraldine, nigraniline, andpemigraniline, depending on the ratio of amine groups to imine groupspresent in the backbone of the polymer. In addition, each oxidativestate may or may not be protonated. For example, the emeraldine saltform of polyaniline, in which about 50 percent of the nitrogen atoms arecontained in imine groups and are protonated, is a very conductive andstable form of a protonated polyaniline. The nonconductive base of thisoxidative state is blue in color, while the protonated form (emeraldinesalt) is green.

[0080] The ICP may be doped by any suitable method. The effectiveness ofthe various doping methods and the conductivity of the doped ICPobtained thereby may vary depending on the doping method, the particularICP, the particular dopant(s), and the point in a composite fabricationprocess at which the ICP is doped (if the ICP is used to prepare acomposite). The ICP may be doped, for example, by mixing a solution,melt, or dispersion of the dopant(s) with the ICP either in solution orwith the ICP in the solid state, contacting a solid ICP with soliddopant(s) (solid state doping), by contacting a solid ICP with dopant(s)in vapor form, or any combination of these.

[0081] In general, polyaniline will reach a maximum conductivity when itis supplied in an amount sufficient to dope about 50 mole percent of theavailable sites. Other types of ICPs will typically reach a maximumconductivity at a somewhat lower level of doping such as, for example,about 30 mole percent of the available sites for polypyrroles andpolythiophenes. The molar amount of dopant necessary to reach themaximum conductivity for the ICP will depend on: (1) the particular ICPutilized, (2) its chemical purity, and (3) the physical distribution ofthe dopant within the ICP matrix. Preferably, the amount of dopantutilized does not greatly exceed the amount which is needed to dope thepolymer for cost reasons, and because the excess dopant may have anexceptionally large tendency to leach out of the composite containingthe doped polymer and excess dopant.

[0082] Examples of suitable dopants for polyaniline and other ICPsinclude any salt, compound, or polymer capable of introducing a chargedsite on the polymer, including both partial and full-charge transfersuch as, Lewis acids, Lowry-Brønsted acids, and certain alkali metalsalts such as lithium tetrafluoroborate, and transition metal salts suchas gold, iron, and platinum chlorides; and other redox agents having asufficiently oxidizing oxidative couple to dope the polymer; alkyl oraryl halides; and acid anhydrides. Not all of the dopants listed abovewill dope each type of ICP; however, appropriate dopants for the ICPslisted above are known in the art or may be readily determinedexperimentally.

[0083] Examples of dopants which are alkylation agents include thosecorresponding to the formula R—X, wherein R is a C₁₋₂₀ hydrocarbyl groupcontaining one or more alkyl, aryl, or benzyl substituents, and X is Cl,Br, or I. Examples of such alkylation agents include methyl iodide andbenzyl bromide. Other examples of suitable alkylation agents includethose corresponding to the formula R¹—X, wherein R¹ is polystyrene,poly(ethylene-styrene), and X is Cl, Br, or I. Examples includehalomethylated polystyrene or poly(ethylene-styrene), and brominatedcopolymer of para-methylstyrene and isobutylene (available from Exxon asExxPro).

[0084] Examples of suitable dopants which are acid anhydrides includemaleic anhydride, phthalic anhydride, and acetic anhydride. Otherexamples include acid anhydrides such as an alternating copolymer ofmaleic anhydride and 1-octadecene (available from Aldrich Chemical),copolymers of maleic anhydride and styrene, and maleic anhydride-graftedpolymers such as polyethylene-grafted maleic anhydride.

[0085] Examples of suitable dopants which are Lewis acids andLowry-Brønsted acids include those described in U.S. Pat. No. 5,160,457,the “functionalized protonic acids” described in U.S. Pat. No. 5,232,631and the “polymeric dopants” described in U.S. Pat. No. 5,378,402, all ofwhich are hereby incorporated by reference. Specific examples of suchacids include all organic sulfonic and carboxylic acids, such asdodecylbenzenesulfonic acid, toluenesulfonic acids,hydroxybenzenesulfonic acid (HBSA), picric acid, m-nitrobenzoic acids,dichloroacetic acid. In addition, acids such as hydrogen chloride,sulfuric acid, nitric acid, HClO₄, HBF₄, HPF₆, HF, phosphoric acidsselenic acid, boronic acid, can also be used as can inorganic clustersof polyoxometallates.

[0086] Examples of polymeric dopants include polymers having terminal orpendant carbon-, phosphorous-, or sulfulr-containing acid groups, andsalts and esters thereof, or mixtures thereof. Specific examples includeethylene/acrylic acid copolymers, polyacrylic acids,ethylene/methacrylic acid copolymers, carboxylic acid- or sulfonicacid-functional polystyrene, polyalkylene oxides, and polyesters; andgraft copolymers of polyethylene or polypropylene and acrylic acid ormaleic anhydride as well as mixtures thereof; sulfonated polycarbonates,sulfonated ethylene-propylene-diene terpolymers (EPDM), sulfonatedethylene-styrene copolymers, polyvinylsulfonic acid, sulfonatedpoly(phenylene oxide), and sulfonated polyesters such as polyethyleneterephthalate; as well as the certain alkali metal and transition metal,salts of such acids, preferably the lithium, manganese, and zinc saltsof such acids. Sulfonated polycarbonates may be prepared, for example,by the methods described in U.S. Pat. No. 5,644,017 and U.S. patentapplication Ser. No. 08/519,853, filed Aug. 25, 1995, entitled “A NovelAromatic Sulfonated Diester Monomer, Process to Synthesize, PolymerDerived Therefrom and Method to Prepare Said Polymer”, which is hereinincorporated by reference.

[0087] c) Conductive Metals and Alloys

[0088] Also included as conductive additives in the blend compositionsof the present invention are metals and alloys including but not limitedto iron, nickel, steel, aluminum, copper, zinc, lead, bronze, brass,zirconium, tin, silver, and gold. These can be in the form of powders,fibres, flakes, or metallized coatings onto substrates such as carbonfibres, glass beads, polymer beads, talcs, or ceramic beads.

[0089] d) Semiconductors and Conducting Inorganic Compounds

[0090] Also included as conductive additives in the blend compositionsof the present invention are semiconductors including but not limited todoped and undoped metal oxides and nitrides. Compounds which arefrequently used commercially include, but are not limited to, tin oxide,indium doped tin oxide, antimony doped tin oxide (for example andSN-100P supplied by the Nagase America Corporation, New York) and thetitanium dioxide (TiO₂)-coated with antimony doped tin oxides having acore and a rutile type acicular shape (for example FT-1000, FT-2000,FT-3000) or a spherical shape (for example ET-300W, ET-500W alsosupplied by the Nagase America Corporation), indium oxide and tin-dopedindium oxide, fluorine doped tin oxide, zinc oxide, and cadmiumstannate, tantalum oxide, and aluminum nitride and doped titaniumdioxide. As conductive additives these materials can be used asparticles, fibres, flakes, or coatings onto substrates such as carbonfibres, glass beads, polymer beads, talcs, ceramic beads, andferromagnetic particles.

[0091] e) Conductive Polymer Electrolytes

[0092] Polymer electrolytes are a class of ionically conductive solids,which may in some cases have sufficient mechanical and electricalproperties to be of commercial use. Many polar polymers are found toform complexes with metal salts and reach useful conductivity values,with mainly LiClO₄, LiCF₃SO₃, LiAsF₆, NaClO₄, NiBr₂, and Ag salts. Inaddition to the polymer/metal salt complexes there may be an amount ofplasticizers which enhance the conductivity, including but not limitedto polyethylene glycoldimethylether (PEGDME) especially in PEO, andpolyethylene glycol and glycoldimethyl ether, and residual solvents suchas water, THF, and alcohols. Representatives polymers of suchpolymer/metal salt complexes are poly(ethylene oxide) (PEO), crosslinkedpoly(ethylene oxide), poly(ethylene glycol/siloxane), which may or maynot be crosslinked, poly(proplyene oxide) (PPO), poly(ethylenesuccinate) (PES), poly(aziridine), poly(N-methylaziridine),poly(methyllene sulfide), poly(bis-methoxy-ethoxy-ethoxy)phosphazene,poly(ethylene adipate), poly(oligo oxyethylene) methacrylate,poly(propiolactone), poly(dioxolane-co-trioxymethylene),poly(fluoro)sulfonic acid such as those commercially available from DuPont under the trade name Nafion™.

[0093] f) Other Conductive Additives

[0094] Also included as conductive additives in the blend compositionsof the present invention are the chopped or non-chopped carbon andgraphite fibers, graphite, cotton fiber braid on a graphite impregnatedglass layer, particulate fillers of a given structure, for example theperovskite and spinel structures, metallized particles, platelet-shapedconductive particles, and may also include some photoconductiveadditives, such as zinc oxide. Also included are antistatic agents whichcan be added separately, or in combination. Examples of antistaticagents include, but are not limited to, the alkyl amines, such asARMOSTAT™ 410, ARMOSTAT™ 450, ARMOSTAT™ 475, all commercially availablefrom Akzo Nobel Corporation; quaternary ammonium compounds, such asMARKSTAT™ which is commercially available from The Argus Corporation,and salts such as LiPF₆, KPF₆, lauryl pyridinium chloride, and sodiumcetyl sulphate, which can be purchased from any ordinary chemicalcatalog, glycerol esters, sorbitan esters, ethoxylated amines.

[0095] 2) High Magnetic Permeability Additives

[0096] In addition to electrical conductivity, the conductive additivemay or may not have a high magnetic permeability, for example iron isboth electrically conductive and has a high magnetic permeability, whilecopper has high conductivity but low magnetic permeability. For thepurposes of this invention the phrase “high magnetic permeability” meansa magnetic permeability of about twenty times greater, preferably abouta hundred times greater than that of copper. Magnetic particles areknown to have superior electromagnetic wave adsorption characteristics,based on well established electromagnetic wave theories.

[0097] Some of these materials have also found a degree of usecommercially. For example, recent patents (U.S. Pat. Nos. 5,206,459;5,262,591, and 5,171,937 all by M. Aldissi of the Champlain CableCorporation and herein incorporated by reference) have described theexceptionally facile dispersion of ferrite particles within polymericmatrices. The ferromagnetic particles may be irregularly or sphericallyshaped. It has been suggested, however, that spherically shapedparticles produce a composite matrix which has better electromagneticadsorption characteristics in comparison to composites based onparticles having irregular shapes. Additionally, the ferromagneticparticles may or may not be coated with a conductive metal layer,including, but not limited to, coatings of Cu and Ag. In general themagnetic particles may include, but are not limited to, magnetite,ferric oxide (Fe₃O₄), MnZn ferrite, and silver-coated manganese-zincferrite to particles. Magnetic particles are manufactured by variouscompanies such as Fair-Rite Products Corporation of N.Y., and theSteward Manufacturing Company of Tennessee. Metal coatings on theseparticles (such as silver) are provided by companies such as PottersIndustries Inc. of Parsippany, N.J.

[0098] The Other Polymer Component (Component C)

[0099] The increase in electrical conductivity or magnetic permeabilityobserved on adding a conductive additive to the substantially randomα-olefin/vinyl or vinylidene interpolymers can also be observed in thepresence of one or more other polymer components which span a wide rangeof compositions.

[0100] The α-Olefin Homopolymers and Interpolymers

[0101] The α-olefin homopolymers and interpolymers comprisepolypropylene, propylene/C₄-C₂₀ α-olefin copolymers, polyethylene, andethylene/C₃-C₂₀ α-olefin copolymers, the interpolymers can be eitherheterogeneous ethylene/α-olefin interpolymers or homogeneousethylene/α-olefin interpolymers, including the substantially linearethylene/α-olefin interpolymers. Also included are aliphatic α-olefinshaving from 2 to 20 carbon atoms and containing polar groups.

[0102] Also included in this group are olefinic monomers which introducepolar groups into the polymer include, for example, ethylenicallyunsaturated nitriles such as acrylonitrile, methacrylonitrile,ethacrylonitrile, etc.; ethylenically unsaturated anhydrides such asmaleic anhydride; ethylenically unsaturated amides such as acrylamide,methacrylamide etc.; ethylenically unsaturated carboxylic acids (bothmono- and difunctional) such as acrylic acid and methacrylic acid, etc.;esters (especially lower, e.g. C₁-C₆, alkyl esters) of ethylenicallyunsaturated carboxylic acids such as methyl methacrylate, ethylacrylate, hydroxyethylacrylate, n-butyl acrylate or methacrylate,2-ethyl-hexylacrylate, or ethylene-vinyl acetate copolymers (EVA) etc.;ethylenically unsaturated dicarboxylic acid imides such as N-alkyl orN-aryl maleimides such as N-phenyl maleimide, etc. Preferably suchmonomers containing polar groups are EVA, acrylic acid, vinyl acetate,maleic anhydride and acrylonitrile.

[0103] Heterogeneous interpolymers are differentiated from thehomogeneous interpolymers in that in the latter, substantially all ofthe interpolymer molecules have the same ethylene/comonomer ratio withinthat interpolymer, whereas heterogeneous interpolymers are those inwhich the interpolymer molecules do not have the same ethylene/comonomerratio. The term “broad composition distribution” used herein describesthe comonomer distribution for heterogeneous interpolymers and meansthat the heterogeneous interpolymers have a “linear” fraction and thatthe heterogeneous interpolymers have multiple melting peaks (i.e.,exhibit at least two distinct melting peaks) by DSC. The heterogeneousinterpolymers have a degree of branching less than or equal to 2methyls/1000 carbons in about 10 percent (by weight) or more, preferablymore than about 15 percent (by weight), and especially more than about20 percent (by weight). The heterogeneous interpolymers also have adegree of branching equal to or greater than 25 methyls/1000 carbons inabout 25 percent or less (by weight), preferably less than about 15percent (by weight), and especially less than about 10 percent (byweight).

[0104] The Ziegler catalysts suitable for the preparation of theheterogeneous component of the current invention are typical supported,Ziegler-type catalysts. Examples of such compositions are those derivedfrom organomagnesium compounds, alkyl halides or aluminum halides orhydrogen chloride, and a transition metal compound. Examples of suchcatalysts are described in U.S. Pat. Nos. 4,314,912 (Lowery, Jr. etal.), 4,547,475 (Glass et al.), and 4,612,300 (Coleman, III), theteachings of which are incorporated herein by reference.

[0105] Suitable catalyst materials may also be derived from a inertoxide supports and transition metal compounds. Examples of suchcompositions are described in U.S. Pat. No. 5,420,090 (Spencer. et al.),the teachings of which are incorporated herein by reference.

[0106] The heterogeneous polymer component can be a homolymer ofethylene or an α-olefin preferably polyethylene or polypropylene, or,preferably, an interpolymer of ethylene with at least one C₃-C₂₀α-olefin and/or C₄-C₁₈ dienes. Heterogeneous copolymers of ethylene, andpropylene, 1-butene, 1-hexene, 4-methyl-1-pentene and 1-octene areespecially preferred.

[0107] The relatively recent introduction of metallocene-based catalystsfor ethylene/α-olefin polymerization has resulted in the production ofnew ethylene interpolymers known as homogeneous interpolymers.

[0108] The homogeneous interpolymers useful for forming the compositionsdescribed herein have homogeneous branching distributions. That is, thepolymers are those in which the comonomer is randomly distributed withina given interpolymer molecule and wherein substantially all of theinterpolymer molecules have the same ethylene/comonomer ratio withinthat interpolymer. The homogeneity of the polymers is typicallydescribed by the SCBDI (Short Chain Branch Distribution Index) or CDBI(Composition Distribution Branch Index) and is defined as the weightpercent of the polymer molecules having a comonomer content within 50percent of the median total molar comonomer content. The CDBI of apolymer is readily calculated from data obtained from techniques knownin the art, such as, for example, temperature rising elutionfractionation (abbreviated herein as “TREF”) as described, for example,in Wild et al, Journal of Polymer Science, Poly. Phys. Ed., Vol. 20, p.441 (1982), in U.S. Pat. No. 4,798,081 (Hazlitt et al.), or as isdescribed in U.S. Pat. No. 5,008,204 (Stehling), the disclosure of whichis incorporated herein by reference. The technique for calculating CDBIis described in U.S. Pat. No. 5,322,728 (Davey et al. ) and in U.S. Pat.No. 5,246,783 (Spenadel et al.). or in U.S. Pat. No. 5,089,321 (Chum etal.) the disclosures of all of which are incorporated herein byreference. The SCBDI or CDBI for the homogeneous interpolymers used inthe present invention is preferably greater than about 30 percent,especially greater than about 50 percent.

[0109] The homogeneous interpolymers used in this invention essentiallylack a measurable “high density” fraction as measured by the TREFtechnique (i.e., the homogeneous ethylene/α-olefin interpolymers do notcontain a polymer fraction with a degree of branching less than or equalto 2 methyls/1000 carbons). The homogeneous interpolymers also do notcontain any highly short chain branched fraction (i.e., they do notcontain a polymer fraction with a degree of branching equal to or morethan 30 methyls/1000 carbons).

[0110] The substantially linear ethylene/α-olefin polymers andinterpolymers blend components of the present invention are alsohomogeneous interpolymers but are further herein defined as in U.S. Pat.No. 5,272,236 (Lai et al.), and in U.S. Pat. No. 5,272,872, the entirecontents of which are incorporated by reference. Such polymers areunique however due to their excellent processability and uniquerheological properties and high melt elasticity and resistance to meltfracture. These polymers can be successfully prepared in a continuouspolymerization process using the constrained geometry metallocenecatalyst systems.

[0111] The term “substantially linear” ethylene/α-olefin interpolymermeans that the polymer backbone is substituted with about 0.01 longchain branches/1000 carbons to about 3 long chain branches/1000 carbons,more preferably from about 0.01 long chain branches/1000 carbons toabout 1 long chain branches/1000 carbons, and especially from about 0.05long chain branches/1000 carbons to about 1 long chain branches/1000carbons.

[0112] Long chain branching is defined herein as a chain length of atleast one carbon more than two carbons less than the total number ofcarbons in the comonomer, for example, the long chain branch of anethylene/octene substantially linear ethylene interpolymer is at leastseven (7) carbons in length (i.e., 8 carbons less 2 equals 6 carbonsplus one equals seven carbons long chain branch length). The long chainbranch can be as long as about the same length as the length of thepolymer back-bone. Long chain branching is determined by using ¹³Cnuclear magnetic resonance (NMR) spectroscopy and is quantified usingthe method of Randall (Rev. Macromol. Chem. Phys., C29 (2&3), p.285-297), the disclosure of which is incorporated herein by reference.Long chain branching, of course, is to be distinguished from short chainbranches which result solely from incorporation of the comonomer, so forexample the short chain branch of an ethylene/octene substantiallylinear polymer is six carbons in length, while the long chain branch forthat same polymer is at least seven carbons in length.

[0113] The catalysts used to prepare the homogeneous interpolymers foruse as blend components in the present invention are metallocenecatalysts. These metallocene catalysts include thebis(cyclopentadienyl)-catalyst systems and the mono(cyclopentadienyl)Constrained Geometry catalyst systems (used to prepare the substantiallylinear ethylene/α-olefin polymers). Such constrained geometry metalcomplexes and methods for their preparation are disclosed in U.S.application Ser. No. 545,403, filed Jul. 3, 1990 (EP-A-416,815); U.S.application Ser. No. 547,718, filed Jul. 3, 1990 (EP-A-468,651); U.S.application Ser. No. 702,475, filed May 20, 1991 (EP-A-514,828); as wellas U.S. Pat. No. 5,055,438, U.S. Pat. No. 5,057,475, U.S. Pat. No.5,096,867, U.S. Pat. No. 5,064,802, U.S. Pat. No. 5,132,380, U.S. Pat.No. 5,721,185, U.S. Pat. No. 5,374,696 and U.S. Pat. No. 5,470,993. Forthe teachings contained therein, the aforementioned pending U.S. patentapplications, issued U.S. patents and published European PatentApplications are herein incorporated in their entirety by referencethereto.

[0114] In EP-A 418,044, published Mar. 20, 1991 (equivalent to U.S. Ser.No. 07/758,654) and in U.S. Ser. No. 07/758,660 certain cationicderivatives of the foregoing constrained geometry catalysts that arehighly useful as olefin polymerization catalysts are disclosed andclaimed. In U.S. Ser. No. 720,041, filed Jun. 24, 1991, certain reactionproducts of the foregoing constrained geometry catalysts with variousboranes are disclosed and a method for their preparation taught andclaimed. In U.S. Pat. No. 5,453,410 combinations of cationic constrainedgeometry catalysts with an alumoxane were disclosed as suitable olefinpolymerization catalysts. For the teachings contained therein, theaforementioned pending U.S. patent applications, issued U.S. patents andpublished European Patent Applications are herein incorporated in theirentirety by reference thereto.

[0115] The homogeneous polymer component can be an ethylene or α-olefinhomopolymer preferably polyethylene or polypropylene, or, preferably, aninterpolymer of ethylene with at least one C₃-C₂₀ a-olefin and/or C₄-C₁₈dienes. Homogeneous copolymers of ethylene, and propylene, 1-butene,1-hexene, 4-methyl-1-pentene and 1-octene are especially preferred.

[0116] 2) Thermoplastic Olefins

[0117] Thermoplastic olefins (TPOs) are generally produced from blendsof an elastomeric material such as ethylene/propylene rubber (EPM) orethylene/propylene diene monomer terpolymer (EPDM) and a more rigidmaterial such as isotactic polypropylene. Other materials or componentscan be added into the formulation depending upon the application,including oil, fillers, and cross-linking agents. Generally, TPOs arecharacterized by a balance of stiffness (modulus) and low temperatureimpact, good chemical resistance and broad use temperatures. Because offeatures such as these, TPOs are used in many applications, includingautomotive facia and instrument panels, and also potentially in wire andcable.

[0118] The polypropylene is generally in the isotactic form ofhomopolymer polypropylene, although other forms of polypropylene canalso be used (e.g., syndiotactic or atactic). Polypropylene impactcopolymers (e.g., those wherein a secondary copolymerization stepreacting ethylene with the propylene is employed) and random copolymers(also reactor modified and usually containing 1.5-7% ethylenecopolymerized with the propylene), however, can also be used in the TPOformulations disclosed herein. In-reactor TPO's can also be used asblend components of the present invention. A complete discussion ofvarious polypropylene polymers is contained in Modern PlasticsEncyclopedia/89, mid October 1988 Issue, Volume 65, Number 11, pp.86-92, the entire disclosure of which is incorporated herein byreference. The molecular weight of the polypropylene for use in thepresent invention is conveniently indicated using a melt flowmeasurement according to ASTM D-1238, Condition 230° C./2.16 kg(formerly known as “Condition (L)” and also known as I₂). Melt flow rateis inversely proportional to the molecular weight of the polymer. Thus,the higher the molecular weight, the lower the melt flow rate, althoughthe relationship is not linear. The melt flow rate for the polypropyleneuseful herein is generally from about 0.1 grams/10 minutes (g/10 min) toabout 35 g/10 min, preferably from about 0.5 g/10 min to about 25 g/10min, and especially from about 1 g/10 min to about 20 g/10 min.

[0119] 3) Styrene-Diene Copolymers

[0120] Also included are block copolymers having unsaturated rubbermonomer units includes, but is not limited to, styrene-butadiene (SB),styrene-isoprene(SI), styrene-butadiene-styrene (SBS),styrene-isoprene-styrene (SIS),α-methylstyrene-butadiene-α-methylstyrene andα-methylstyrene-isoprene-α-methylstyrene.

[0121] The styrenic portion of the block copolymer is preferably apolymer or interpolymer of styrene and its analogs and homologsincluding α-methylstyrene and ring-substituted styrenes, particularlyring-methylated styrenes. The preferred styrenics are styrene andα-methylstyrene, and styrene is particularly preferred.

[0122] Block copolymers with unsaturated rubber monomer units maycomprise homopolymers of butadiene or isoprene or they may comprisecopolymers of one or both of these two dienes with a minor amount ofstyrenic monomer.

[0123] Preferred block copolymers with saturated rubber monomer unitscomprise at least one segment of a styrenic unit and at least onesegment of an ethylene-butene or ethylene-propylene copolymer. Preferredexamples of such block copolymers with saturated rubber monomer unitsinclude styrene/ethylene-butene copolymers, styrene/ethylene-propylenecopolymers, styrene/ethylene-butene/styrene (SEBS) copolymers,styrene/ethylene-propylene/styrene (SEPS) copolymers.

[0124] Also included are random copolymers having unsaturated rubbermonomer units includes, but is not limited to, styrene-butadiene (SB),styrene-isoprene(SI), α-methylstyrene-styrene-butadiene,α-methylstyrene-styrene-isoprene, and styrene-vinyl-pyridine-butadiene.

[0125] 4) Styrenic Copolymers

[0126] In addition to the block and random styrene copolymers are theacrylonitrile-butadiene-styrene (ABS) polymers, styrene-acrylonitrile(SAN), rubber modified styrenics such as high impact polystyrene,

[0127] 5) Elastomers

[0128] The elastomers include but are not limited to rubbers such aspolyisoprene, polybutadiene, natural rubbers, ethylene/propylenerubbers, ethylene/propylene diene (EPDM) rubbers, thermoplasticpolyurethanes, silicone rubbers, and.

[0129] 6) Thermoset Polymers

[0130] The thermoset polymers include but are not limited to epoxies,vinyl ester resins, polyurethanes, phenolics and the like.

[0131] 7) Vinyl Halide Polymers

[0132] Vinyl halide homopolymers and copolymers are a group of resinswhich use as a building block the vinyl structure CH₂═CXY, where X isselected from the group consisting of F, Cl, Br, and I and Y is selectedfrom the group consisting of F, Cl, Br, I and H.

[0133] The vinyl halide polymer component of the blends of the presentinvention include but are not limited to homopolymers and copolymers ofvinyl halides with copolymerizable monomers such as α-olefins includingbut not limited to ethylene, propylene, vinyl esters of organic acidscontaining 1 to 18 carbon atoms, e.g. vinyl acetate, vinyl stearate andso forth; vinyl chloride, vinylidene chloride, symmetricaldichloroethylene; acrylonitrile, methacrylonitrile; alkyl acrylateesters in which the alkyl group contains 1 to 8 carbon atoms, e.g.methyl acrylate and butyl acrylate; the corresponding alkyl methacrylateesters; dialkyl esters of dibasic organic acids in which the alkylgroups contain 1-8 carbon atoms, e.g. dibutyl fumarate, diethyl maleate,and so forth.

[0134] Preferably the vinyl halide polymers are homopolymers orcopolymers of vinyl chloride or vinylidene dichloride. Poly (vinylchloride) polymers (PVC) can be further classified into two main typesby their degree of rigidity. These are “rigid” PVC and “flexible” PVC.Flexible PVC is distinguished from rigid PVC primarily by the presenceof and amount of plasticizers in the resin. Flexible PVC typically hasimproved processability, lower tensile strength and higher elongationthan rigid PVC.

[0135] Of the vinylidene chloride homopolymers and copolymers (PVDC),typically the copolymers with vinyl chloride, acrylates or nitrites areused commercially and are most preferred. The choice of the comonomersignificantly affects the properties of the resulting polymer. Perhapsthe most notable properties of the various PVDC's are their lowpermeability to gases and liquids, barrier properties; and chemicalresistance.

[0136] Also included are the various PVC and PVCD formulationscontaining minor amounts of other materials present to modify theproperties of the PVC or PVCD, including but not limited to polystyrene,styrenic copolymers, polyolefins including homo and copolymerscomprising polyethylene, and or polypropylene, and otherethylene/α-olefin copolymers, polyacrylic resins, butadiene-containingpolymers such as acrylonitrile butadiene styrene terpolymers (ABS), andmethacrylate butadiene styrene terpolymers (MBS), and chlorinatedpolyethylene (CPE) resins and the like.

[0137] Also included in the family of vinyl halide polymers for use asblend components of the present invention are the chlorinatedderivatives of PVC typically prepared by post chlorination of the baseresin and known as chlorinated PVC, (CPVC). Although CPVC is based onPVC and shares some of its characteristic properties, CPVC is a uniquepolymer having a much higher melt temperature range (410-450° C.) and ahigher glass transition temperature (239-275° F.) than PVC.

[0138] 8) Engineering Thermoplastics

[0139] Engineering thermoplastics include but are not limited topoly(methylmethacrylate) (PMMA), nylons, poly(acetals), polystyrene(atactic and syndiotactic), polycarbonate, thermoplastic polyurethanes,polysiloxane, polyphenylene oxide (PPO), and aromatic polyesters.

[0140] Other Additives

[0141] Other additives such as antioxidants (e.g., hindered phenols suchas, for example, Irganox® 1010), phosphites (e.g., Irgafos® 168), U.V.stabilizers, cling additives (e.g., polyisobutylene), antiblockadditives, colorants, pigments, fillers, and the like can also beincluded in the interpolymers employed in the blends of and/or employedin the present invention, to the extent that they do not interfere withthe enhanced properties discovered by Applicants.

[0142] Preferred inorganic fillers are ionic inorganic materials.Preferred examples of inorganic fillers are talc, calcium carbonate,alumina trihydrate, glass fibers, marble dust, cement dust, clay,feldspar, silica or glass, fumed silica, alumina, magnesium oxide,magnesium hydroxide, antimony oxide, zinc oxide, barium sulfate,aluminum silicate, calcium silicate, titanium dioxide, titanates, glassmicrospheres or chalk. Of these fillers, barium sulfate, talc, calciumcarbonate, silica/glass, glass fibers, alumina and titanium dioxide, andmixtures thereof are preferred. The most preferred inorganic fillers aretalc, calcium carbonate, barium sulfate, glass fibers or mixturesthereof. Additives such as fillers also play a role in the aesthetics ofa final article providing a gloss or matte finish.

[0143] These additives are employed in functionally equivalent amountsknown to those skilled in the art. For example, the amount ofantioxidant employed is that amount which prevents the polymer orpolymer blend from undergoing oxidation at the temperatures andenvironment employed during storage and ultimate use of the polymers.Such amount of antioxidants is usually in the range of from 0.01 to 10,preferably from 0.05 to 5, more preferably from 0.1 to 2 percent byweight based upon the weight of the polymer or polymer blend. Similarly,the amounts of any of the other enumerated additives are thefunctionally equivalent amounts such as the amount to render the polymeror polymer blend antiblocking, to produce the desired amount of fillerloading to produce the desired result, to provide the desired color fromthe colorant or pigment. Such additives can suitably be employed in therange of from 0.05 to 50, preferably from 0.1 to 35, more preferablyfrom 0.2 to 20 percent by weight based upon the weight of the polymer orpolymer blend. However, in the instance of fillers, they could beemployed in amounts up to 90 percent by weight based on the weight ofthe polymer or polymer blend. The preferred amounts of inorganic fillerdepend on the desired end-use of the filled polymer compositions of thepresent invention.

[0144] For example, when producing floor, wall or ceiling tiles, theamount of the inorganic filler(s) (B) preferably is from about 50 toabout 95 percent, more preferably from about 70 to about 90 percent,based on the total weight of (A) and (B). On the other hand, whenproducing floor, wall or ceiling sheetings, the amount of the inorganicfiller(s) (B) preferably is from about 10 to about 70 percent, morepreferably from about 15 to about 50 percent, based on the total weightof (A) and (B). For several applications filler contents of from about40 to about 90 percent, more preferably from about 55 to about 85percent, based on the total weight of (A) and (B), are preferred.

[0145] In addition, flow and dispersions aids for the conductiveadditive may be used including, titanates and zirconates, variousprocessing oils and low molecular weight polymers and waxes such aspoly(ethyleneoxide), and organic salts such as zinc and calciumstearate.

[0146] Preparation of and Applications for, the Final Blend Compositions

[0147] The interpolymers of α-olefin monomers with one or more vinyl orvinylidene aromatic monomers and/or one or more hindered aliphatic orcycloaliphatic vinyl or vinylidene monomers with the conductive or highmagnetic permeability additive can be used alone, or as a masterbatch orconcentrate for addition to other polymers, or as a coating for numerousapplications. Such blends can be thermally or solution processed, andcan be modified to have low or high conductivity, with the requisitelevel depending upon the particular application.

[0148] The compositions of the present invention can be prepared by anyconvenient method, including dry blending the individual components andsubsequently melt mixing or melt compounding, either directly in theextruder or mill used to make the finished article (e.g., the automotivepart), or by pre-melt mixing in a separate extruder or mill (e.g., aBanbury mixer), or by solution blending, or by compression molding, orby calendering. In addition to melt processing, solution processing canalso be utilized. This includes but is not limited to mixing ofdissolved polymers or of dispersions such as latexes and colloids.

[0149] There are many types of molding operations which can be used toform useful fabricated articles or parts from the present compositions,including casting from solution, thermoforming and various injectionmolding processes (e.g., that described in Modern PlasticsEncyclopedia/89, Mid October 1988 Issue, Volume 65, Number 11, pp.264-268, “Introduction to Injection Molding” and on pp. 270-271,“Injection Molding Thermoplastics”, the disclosures of which areincorporated herein by reference) and blow molding processes (e.g., thatdescribed in Modern Plastics Encyclopedia/89, Mid October 1988 Issue,Volume 65, Number 11, pp. 217-218, “Extrusion-Blow Molding”, thedisclosure of which is incorporated herein by reference) and profileextrusion, sheet extrusion, film casting, coextrusion and multilayerextrusion, coinjection molding, lamination, film blowing.

[0150] The compositions of the present invention may be used to formexpandable or foamable particles, moldable foam particles, or beads, andarticles formed by expansion and/or coalescing and welding of thoseparticles.

[0151] The compositions of the present invention may be used to formfoam structures which may take any physical configuration known in theart, such as sheet, plank, profiles, rods or bun stock. Other usefulforms are expandable or foamable particles, moldable foam particles, orbeads, and articles formed by expansion and/or coalescing and welding ofthose particles.

[0152] Excellent teachings to processes for making ethylenic polymerfoam structures and processing them are seen in C. P. Park, “PolyolefinFoam”, Chapter 9, Handbook of Polymer Foams and Technology, edited by D.Klempner and K. C. Frisch, Hanser Publishers, Munich, Vienna, New York,Barcelona (1991), which is incorporated herein by reference.

[0153] Foam structures may be made by a conventional extrusion foamingprocess. The structure is generally prepared by heating the compositionsof the present invention to form a plasticized or melt polymer material,incorporating therein a blowing agent to form a foamable gel, andextruding the gel through a die to form the foam product. Prior tomixing with the blowing agent, the polymer material is heated to atemperature at or above its glass transition temperature or meltingpoint. The blowing agent may be incorporated or mixed into the meltpolymer material by any means known in the art such as with an extruder,mixer, blender, or the like. The blowing agent is mixed with the meltpolymer material at an elevated pressure sufficient to preventsubstantial expansion of the melt polymer material and to generallydisperse the blowing agent homogeneously therein. Optionally, anucleator may be blended in the polymer melt or dry blended with thepolymer material prior to plasticizing or melting. The foamable gel istypically cooled to a lower temperature to optimize physicalcharacteristics of the foam structure. The gel is then extruded orconveyed through a die of desired shape to a zone of reduced or lowerpressure to form the foam structure. The zone of lower pressure is at apressure lower than that in which the foamable gel is maintained priorto extrusion through the die. The lower pressure may be superatmosphericor subatmospheric (vacuum), but is preferably at an atmospheric level.

[0154] The present foam structures may be formed in a coalesced strandform by extrusion of the compositions of the present invention through amulti-orifice die. The orifices are arranged so that contact betweenadjacent streams of the molten extrudate occurs during the foamingprocess and the contacting surfaces adhere to one another withsufficient adhesion to result in a unitary foam structure. The streamsof molten extrudate exiting the die take the form of strands orprofiles, which desirably foam, coalesce, and adhere to one another toform a unitary structure. Desirably, the coalesced individual strands orprofiles should remain adhered in a unitary structure to prevent stranddelamination under stresses encountered in preparing, shaping, and usingthe foam. Apparatuses and method for producing foam structures incoalesced strand form are seen in U.S. Pat. Nos. 3,573,152 and4,824,720, both of which are incorporated herein by reference.

[0155] The present foam structures may also be formed by an accumulatingextrusion process as seen in U.S. Pat. No. 4,323,528, which isincorporated by reference herein. In this process, low density foamstructures having large lateral cross-sectional areas are preparedby: 1) forming under pressure a gel of the compositions of the presentinvention and a blowing agent at a temperature at which the viscosity ofthe gel is sufficient to retain the blowing agent when the gel isallowed to expand; 2) extruding the gel into a holding zone maintainedat a temperature and pressure which does not allow the gel to foam, theholding zone having an outlet die defining an orifice opening into azone of lower pressure at which the gel foams, and an openable gateclosing the die orifice; 3) periodically opening the gate; 4)substantially concurrently applying mechanical pressure by a movable ramon the gel to eject it from the holding zone through the die orificeinto the zone of lower pressure, at a rate greater than that at whichsubstantial foaming in the die orifice occurs and less than that atwhich substantial irregularities in cross-sectional area or shapeoccurs; and 5) permitting the ejected gel to expand unrestrained in atleast one dimension to produce the foam structure.

[0156] The present foam structures may also be formed intonon-crosslinked foam beads suitable for molding into articles. To makethe foam beads, discrete resin particles such as granulated resinpellets are: suspended in a liquid medium in which they aresubstantially insoluble such as water; impregnated with a blowing agentby introducing the blowing agent into the liquid medium at an elevatedpressure and temperature in an autoclave or other pressure vessel; andrapidly discharged into the atmosphere or a region of reduced pressureto expand to form the foam beads. This process is well taught in U.S.Pat. Nos. 4,379,859 and 4,464,484, which are incorporated herein byreference.

[0157] In a derivative of the above process, styrene monomer may beimpregnated into the suspended pellets prior to impregnation withblowing agent to form a graft interpolymer with the compositions of thepresent invention. The polyethylene/polystyrene interpolymer beads arecooled and discharged from the vessel substantially unexpanded. Thebeads are then expanded and molded by the conventional expandedpolystyrene bead molding process. The process of making thepolyethylene/polystyrene interpolymer beads is described in U.S. Pat.No. 4,168,353, which is incorporated herein by reference.

[0158] The foam beads may then be molded by any means known in the art,such as charging the foam beads to the mold, compressing the mold tocompress the beads, and heating the beads such as with steam to effectcoalescing and welding of the beads to form the article. Optionally, thebeads may be impregnated with air or other blowing agent at an elevatedpressure and temperature prior to charging to the mold. Further, thebeads may be heated prior to charging. The foam beads may then be moldedto blocks or shaped articles by a suitable molding method known in theart. (Some of the methods are taught in U.S. Pat. Nos. 3,504,068 and3,953,558.) Excellent teachings of the above processes and moldingmethods are seen in C. P. Park, supra, p. 191, pp. 197-198, and pp.227-229, which are incorporated herein by reference.

[0159] Blowing agents useful in making the present foam structureinclude inorganic agents, organic blowing agents and chemical blowingagents. Suitable inorganic blowing agents include carbon dioxide,nitrogen, argon, water, air, nitrogen, and helium. Organic blowingagents include aliphatic hydrocarbons having 1-6 carbon atoms, aliphaticalcohols having 1-3 carbon atoms, and fully and partially halogenatedaliphatic hydrocarbons having 1-4 carbon atoms. Aliphatic hydrocarbonsinclude methane, ethane, propane, n-butane, isobutane, n-pentane,isopentane, neopentane, and the like. Aliphatic alcohols includemethanol, ethanol, n-propanol, and isopropanol. Fully and partiallyhalogenated aliphatic hydrocarbons include fluorocarbons, chlorocarbons,and chlorofluorocarbons. Examples of fluorocarbons include methylfluoride, perfluoromethane, ethyl fluoride, 1,1-difluoroethane(HFC-152a), 1,1,1-trifluoroethane (HFC-143a), 1,1,1,2-tetrafluoro-ethane(HFC-134a), pentafluoroethane, difluoromethane, perfluoroethane,2,2-difluoropropane, 1,1,1-trifluoropropane, perfluoropropane,dichloropropane, difluoropropane, perfluorobutane, perfluorocyclobutane.Partially halogenated chlorocarbons and chlorofluorocarbons for use inthis invention include methyl chloride, methylene chloride, ethylchloride, 1,1,1-trichloroethane, 1,1-dichloro-1-fluoroethane(HCFC-141b), 1-chloro-1,1 difluoroethane (HCFC-142b),1,1-dichloro-2,2,2-trifluoroethane (HCFC-123) and1-chloro-1,2,2,2-tetrafluoroethane(HCFC-124). Fully halogenatedchlorofluorocarbons include trichloromonofluoromethane (CFC-11),dichlorodifluoromethane (CFC-12), trichlorotrifluoroethane (CFC-113),1,1,1-trifluoroethane, pentafluoroethane, dichlorotetrafluoroethane(CFC-114), chloroheptafluoropropane, and dichlorohexafluoropropane.Chemical blowing agents include azodicarbonamide,azodiisobutyro-nitrile, benezenesulfonhydrazide, 4,4-oxybenzenesulfonyl-semicarbazide, p-toluene sulfonyl semi-carbazide, bariumazodicarboxylate, N,N′-dimethyl-N,N′-dinitrosoterephthalamide, andtrihydrazino triazine. Preferred blowing agents include isobutane,HFC-152a, and mixtures of the foregoing.

[0160] The amount of blowing agents incorporated into the polymer meltmaterial to make a foam-forming polymer gel is from about 0.2 to about5.0, preferably from about 0.5 to about 3.0, and most preferably fromabout 1.0 to 2.50 gram moles per kilogram of polymer.

[0161] Foams may be perforated to enhance or accelerate permeation ofblowing agent from the foam and air into the foam. The foams may beperforated to form channels which extend entirely through the foam fromone surface to another or partially through the foam. The channels maybe spaced up to about 2.5 centimeters apart and preferably up to about1.3 centimeters apart. The channels are present over substantially anentire surface of the foam and preferably are uniformly dispersed overthe surface. The foams may employ a stability control agent of the typedescribed above in combination with perforation to allow acceleratedpermeation or release of blowing agent while maintaining a dimensionallystable foam. Excellent teachings to perforation of foam are seen in U.S.Pat. Nos. 5,424,016 and 5,585,058, which are incorporated herein byreference.

[0162] Various additives may be incorporated in the present foamstructure such as stability control agents, nucleating agents, inorganicfillers, pigments, antioxidants, acid scavengers, ultraviolet absorbers,flame retardants, processing aids, extrusion aids, and the like.

[0163] A stability control agent may be added to the present foam toenhance dimensional stability. Preferred agents include amides andesters of C₁₀₋₂₄ fatty acids. Such agents are seen in U.S. Pat. Nos.3,644,230 and 4,214,054, which are incorporated herein by reference.Most preferred agents include stearyl stearamide, glycerol monostearate,glycerol monobehenate, and sorbitol monostearate. Typically, suchstability control agents are employed in an amount ranging from about0.1 to about 10 parts per hundred parts of the polymer.

[0164] The present foam structure exhibits excellent dimensionalstability. Preferred foams recover 80 or more percent of initial volumewithin a month with initial volume being measured within 30 secondsafter foam expansion. Volume is measured by a suitable method such ascubic displacement of water.

[0165] In addition, a nucleating agent may be added in order to controlthe size of foam cells. Preferred nucleating agents include inorganicsubstances such as calcium carbonate, talc, clay, titanium oxide,silica, barium sulfate, diatomaceous earth, mixtures of citric acid andsodium bicarbonate, and the like. The amount of nucleating agentemployed may range from about 0.01 to about 5 parts by weight perhundred parts by weight of a polymer resin.

[0166] The foam structure can be substantially noncross-linked oruncross-linked. The alkenyl aromatic polymer material comprising thefoam structure is substantially free of cross-linking. The foamstructure contains no more than 5 percent gel per ASTM D-2765-84 MethodA. A slight degree of cross-linking, which occurs naturally without theuse of cross-linking agents or radiation, is permissible.

[0167] The foam structure may also be substantially cross-linked.Cross-linking may be induced by addition of a cross-linking agent or byradiation. Induction of cross-linking and exposure to an elevatedtemperature to effect foaming or expansion may occur simultaneously orsequentially. If a cross-linking agent is used, it is incorporated intothe polymer material in the same manner as the chemical blowing agent.Further, if a cross-linking agent is used, the foamable melt polymermaterial is heated or exposed to a temperature of preferably less than150° C. to prevent decomposition of the cross-linking agent or theblowing agent and to prevent premature cross-linking. If radiationcross-linking is used, the foamable melt polymer material is heated orexposed to a temperature of preferably less than 160° C. to preventdecomposition of the blowing agent. The foamable melt polymer materialis extruded or conveyed through a die of desired shape to form afoamable structure. The foamable structure is then cross-linked andexpanded at an elevated or high temperature (typically, 150° C.-250° C.)such as in an oven to form a foam structure. If radiation cross-linkingis used, the foamable structure is irradiated to cross-link the polymermaterial, which is then expanded at the elevated temperature asdescribed above. The present structure can advantageously be made insheet or thin plank form according to the above process using eithercross-linking agents or radiation.

[0168] The present foam structure may also be made into a continuousplank structure by an extrusion process utilizing a long-land die asdescribed in GB 2,145,961A. In that process, the polymer, decomposableblowing agent and cross-linking agent are mixed in an extruder, heatingthe mixture to let the polymer cross-link and the blowing agent todecompose in a long-land die; and shaping and conducting away from thefoam structure through the die with the foam structure and the diecontact lubricated by a proper lubrication material.

[0169] The present foam structure may also be formed into cross-linkedfoam beads suitable for molding into articles. To make the foam beads,discrete resin particles such as granulated resin pellets are: suspendedin a liquid medium in which they are substantially insoluble such aswater; impregnated with a cross-linking agent and a blowing agent at anelevated pressure and temperature in an autoclave or other pressurevessel; and rapidly discharged into the atmosphere or a region ofreduced pressure to expand to form the foam beads. A version is that thepolymer beads is impregnated with blowing agent, cooled down, dischargedfrom the vessel, and then expanded by heating or with steam. Blowingagent may be impregnated into the resin pellets while in suspension or,alternately, in non-hydrous state. The expandable beads are thenexpanded by heating with steam and molded by the conventional moldingmethod for the expandable polystyrene foam beads.

[0170] The foam beads may then be molded by any means known in the art,such as charging the foam beads to the mold, compressing the mold tocompress the beads, and heating the beads such as with steam to effectcoalescing and welding of the beads to form the article. Optionally, thebeads may be pre-heated with air or other blowing agent prior tocharging to the mold. Excellent teachings of the above processes andmolding methods are seen in C. P. Park, above publication, pp. 227-233,U.S. Pat. No. 3,886,100, U.S. Pat. No. 3,959,189, U.S. Pat. No.4,168,353, and U.S. Pat. No. 4,429,059. The foam beads can also beprepared by preparing a mixture of polymer, cross-linking agent, anddecomposable mixtures in a suitable mixing device or extruder and formthe mixture into pellets, and heat the pellets to cross-link and expand.

[0171] In another process for making cross-linked foam beads suitablefor molding into articles, the substantially random interpolymermaterial is melted and mixed with a physical blowing agent in aconventional foam extrusion apparatus to form an essentially continuousfoam strand. The foam strand is granulated or pelletized to form foambeads. The foam beads are then cross-linked by radiation. Thecross-linked foam beads may then be coalesced and molded to form variousarticles as described above for the other foam bead process. Additionalteachings to this process are seen in U.S. Pat. No. 3,616,365 and C. P.Park, above publication, pp. 224-228.

[0172] The present foam structure may be made in bun stock form by twodifferent processes. One process involves the use of a cross-linkingagent and the other uses radiation.

[0173] The present foam structure may be made in bun stock form bymixing the substantially random interpolymer material, a cross-linkingagent, and a chemical blowing agent to form a slab, heating the mixturein a mold so the cross-linking agent can cross-link the polymer materialand the blowing agent can decompose, and expanding by release ofpressure in the mold. Optionally, the bun stock formed upon release ofpressure may be re-heated to effect further expansion.

[0174] Cross-linked polymer sheet may be made by either irradiatingpolymer sheet with high energy beam or by heating a polymer sheetcontaining chemical cross-linking agent. The cross-linked polymer sheetis cut into the desired shapes and impregnated with nitrogen in a higherpressure at a temperature above the softening point of the polymer;releasing the pressure effects nucleation of bubbles and some expansionin the sheet. The sheet is re-heated at a lower pressure above thesoftening point, and the pressure is then released to allow foamexpansion.

[0175] The foam structure has density of less than 250, more preferablyless than 100 and most preferably from about 10 to about 70 kilogramsper cubic meter. The foam has an average cell size of from about 0.05 toabout 5.0, more preferably from about 0.2 to about 2.0, and mostpreferably 0.3 to about 1.8 millimeters according to ASTM D3576.

[0176] The foam structure may take any physical configuration known inthe art, such as extruded sheet, rod, plank, and profiles. The foamstructure may also be formed by molding of expandable beads into any ofthe foregoing configurations or any other configuration.

[0177] The foam structure may be closed-celled or open-celled.Preferably, the present foam contains 80 percent or more closed cellsaccording to ASTM D2856-A.

[0178] The foams of the present invention will provide protection toelectronic components from damage caused by electrostatic discharge(ESD). Specific antistatic or conductive applications of foams made fromthis invention are as follows: cushion packaging of finished electronicgoods (corner blocks, braces, saddles, pouches, bags, envelopes,overwraps, interleafing, encapsulation); packaging or protection ofexplosive materials or devices in environments where spark dischargescan readily cause detonation; material handling (trays, tote boxes, boxliners, tote box inserts and dividers, shunt, stuffing, boards, partsspacers and parts separators); work station accessories (aprons, tableand bench top covers, floor mats, seat cushions); conductive shoeinsoles. The foams of this invention may also be of utility in thefollowing applications: gaskets, grommets, seals; Faraday cageshielding; direct lead insertion; shunt bars for edge connections; soundattenuation for printers and typewriters; conductive seat cushioning;static control table and floor mats; carpet underlayment (especiallyautomotive); display case insert; missile container padding; militaryshell holder; blocking and bracing of various items in transport;preservation and packaging; automotives anti-rattle pads, seals; medicaldevices, skin contact pads; cushioned pallet; vibration isolation pad.It should be clear, however, that the foams of this invention will notbe limited to the above mentioned applications.

[0179] In addition to foams, the compositions of the present inventionfind utility in all applications which require static charge dissipationor electrical conduction or electromagnetic energy absorption,including, but not limited to;

[0180] 1) shaped articles such as toys, gaskets, films and sheets,photocopier components, as coatings on polymeric substrates, paper,leather, cloth, and inorganic building materials, and as foams for heat,sound, and vibration damping; corrugated boxes, and films and filmreels, connectors and clips;

[0181] 2) transportation applications including but not limited to fueltanks, bumper facia, instrument panels, hood panels, interior andexterior trim and cladding, pillars, bed liners, seating systems, tires,drive belts, electrical connectors, housings, conduit, energy managementsystems such as energy management foam systems, gasoline cans, andignition cables for automobiles;

[0182] 3) construction materials, flooring systems such as mats,carpets, and carpet backings floor tiles, asphalt, concrete bench topsor counter tops;

[0183] 4) EMI shielding in for example wire and cable, cellular phones,computer housings, monitors, projection devices, printers, photocopiers,automotive applications and for use in densely packed electronictelecommunication environments;

[0184] 5) wire and cable for high, medium and low voltage applications,in particular for direct or alternating current applications; forhomogenization of conductors in lightning shielding for undergroundtelecommunication cables;

[0185] 6) durable and electronic goods for example solids handlingequipment and conveyor belts, rudders wing tips and engine pylons,landing gear;

[0186] 7) medical/clothing applications, footwear such as shoes,slippers, boots, and also blankets, gloves, remote handling gloves;

[0187] 8) Multilayered structures including but not limited tomultilayer sheets and films, co-injection molded articles, laminates,fibers, coatings;

[0188] 9) adhesives;

[0189] 10) electromotively coated plastics such as electrostaticallypainted plastics and electroplated plastics;

[0190] 11) binders for conductive inks, printer paper; and

[0191] 12) heating equipment.

[0192] Properties of the Individual Blend Components and the Final BlendCompositions

[0193] a) The Ethylene/Vinyl or Vinylidene Interpolymers

[0194] The interpolymers of one or more α-olefins and one or more vinylor vinylidene aromatic monomers and/or one or more hindered aliphatic orcycloaliphatic vinyl or vinylidene monomers employed in the presentinvention are substantially random polymers. These interpolymers usuallycontain from about 0.5 to about 65, preferably from about 1 to about 55,more preferably from about 2 to about 50 mole percent of at least onevinyl or vinylidene aromatic monomer and/or hindered aliphatic orcycloaliphatic vinyl or vinylidene monomer and from about 35 to about99.5, preferably from about 45 to about 99, more preferably from about50 to about 98 mole percent of at least one aliphatic α-olefin havingfrom 2 to about 20 carbon atoms.

[0195] The number average molecular weight (M_(n)) of theseinterpolymers is usually greater than about 1,000, preferably from about5,000 to about 1,000,000, more preferably from about 10,000 to about500,000.

[0196] The interpolymer(s) applicable to the present invention can havea melt index (I₂) of from about 0.01 to about 1000, preferably of fromabout 0.1 to about 100, more preferably of from about 0.5 to about 50g/10 min.

[0197] The polydispersity ratio M_(w)/M_(n) of the interpolymer(s)applicable to the present invention is from about 1.5 to about, 20,preferably of from about 1.8 to about 10, more preferably of from about2 to about 5.

[0198] While preparing the substantially random interpolymer, an amountof homopolymer may be formed, for example, due to homopolymerization ofthe vinyl or vinylidene aromatic monomer at elevated temperatures. Thepresence of vinyl or vinylidene aromatic homopolymer is in general notdetrimental for the purposes of the present invention and can betolerated. The vinyl or vinylidene aromatic homopolymer may be separatedfrom the interpolymer, if desired, by extraction techniques such asselective precipitation from solution with a non solvent for either theinterpolymer or the vinyl or vinylidene aromatic homopolymer. For thepurpose of the present invention it is preferred that no more than 20weight percent, preferably less than 15 weight percent based on thetotal weight of the interpolymers of atactic vinyl or vinylidenearomatic homopolymer is present.

[0199] b) The Conductive Additive

[0200] The optimum amount of conductive additives depends on theparticular applications.

[0201] For electrically conductive composites there are two regimes ofconductivity which are loosely defined as electrostatically dissipative(ESD) which falls within about 10⁻⁹ S/cm to about 10⁻³ S/cm, preferablyfrom about 10⁻⁹ to about 10⁻² S/cm, and “conductive”(CON) which isdefined here as a conductivity greater than about 10⁻³ S/cm.

[0202] For ESD the amount of electrically conductive additive will befrom about 0.01 to about 50, preferably of from about 0.1 to about 20,more preferably of from about 0.5 to about 12 wt % based on the totalweight of the individual blend components.

[0203] For CON the amount of electrically conductive additive will befrom about 5 to about 70, preferably from about 15 to about 70, morepreferably of from about 20 to about 55, and even more more preferablyof from about 25 to about 45 wt % based on the total weight of theindividual blend components.

[0204] c) The Final Blend Compositions

[0205] The blends comprise of from about 1 to about 99.99 wt % of atleast one substantially random interpolymer (Component A), preferably offrom about 5 to about 97 wt %, more preferably of from about 10 to about94.0 wt % based on the combined weights of Components A, B, and C.

[0206] The blends further comprise 0.01-99 wt % of at least oneconductive additive (Component B), preferably of from about 0.5 to about50 wt %, more preferably of from about 1 to about 25 wt % based on thecombined weights of Components A B and C.

[0207] The blends further comprise 0-98.99 wt. % of at least one polymer(Component C) which is different to Component A and Component Bpreferably of from about 2.5 to about 94.5 wt %, more preferably of fromabout 5 to about 89 wt % based on the combined weights of Components A Band C.

[0208] The following examples are illustrative of the invention, but arenot to be construed as to limiting the scope thereof in any manner.

EXAMPLES Test Methods

[0209] a) Density and Melt Flow Measurements

[0210] The molecular weight of the polymer compositions for use in thepresent invention is conveniently indicated using a melt indexmeasurement according to ASTM D-1238, Condition 190° C./2.16 kg(formally known as “Condition (E)” and also known as I₂) was determined.Melt index is inversely proportional to the molecular weight of thepolymer. Thus, the higher the molecular weight, the lower the meltindex, although the relationship is not linear.

[0211] Also useful for indicating the molecular weight of thesubstantially random interpolymers used in the present invention is theGottfert melt index (G, cm³/10 min) which is obtained in a similarfashion as for melt index (I₂) using the ASTM D1238 procedure forautomated plastometers, with the melt density set to 0.7632, the meltdensity of polyethylene at 190° C.

[0212] The relationship of melt density to styrene content forethylene-styrene interpolymers was measured, as a function of totalstyrene content, at 190° C. for a range of 29.8% to 81.8% by weightstyrene. Atactic polystyrene levels in these samples was typically 10%or less. The influence of the atactic polystyrene was assumed to beminimal because of the low levels. Also, the melt density of atacticpolystyrene and the melt densities of the samples with high totalstyrene are very similar. The method used to determine the melt densityemployed a Gottfert melt index machine with a melt density parameter setto 0.7632, and the collection of melt strands as a function of timewhile the I₂ weight was in force. The weight and time for each meltstrand was recorded and normalized to yield the mass in grams per 10minutes. The instrument's calculated I₂ melt index value was alsorecorded. The equation used to calculate the actual melt density is

δ=δ_(0.7632) ×I ₂ /I ₂Gottfert

[0213] where δ_(0.7632)=0.7632 and I₂ Gottfert=displayed melt index.

[0214] A linear least squares fit of calculated melt density versustotal styrene content leads to an equation with a correlationcoefficient of 0.91 for the following equation:

δ=0.00299×S+0.723

[0215] where S=weight percentage of styrene in the polymer. Therelationship of total styrene to melt density can be used to determinean actual melt index value, using these equations if the styrene contentis known.

[0216] For a polymer that is 73% total styrene content with a measuredmelt flow (the “Gottfert number”), the calculation becomes:

x=0.00299*73+0.723=0.9412

[0217] where 0.9412/0.7632=I₂/G#(measured)=1.23

[0218] The density of the substantially random interpolymers used in thepresent invention was determined in accordance with ASTM D-792.

[0219] b) ¹³C—NMR Chemical Shifts

[0220] In order to determine the carbon⁻¹³ NMR chemical shifts of theinterpolymers described, the following procedures and conditions areemployed. A five to ten weight percent polymer solution is prepared in amixture consisting of 50 volume percent 1,1,2,2-tetrachloroethane-d₂ and50 volume percent 0.10 molar chromium tris(acetylacetonate) in1,2,4-trichlorobenzene. NMR spectra are acquired at 130° C. using aninverse gated decoupling sequence, a 90° pulse width and a pulse delayof five seconds or more. The spectra are referenced to the isolatedmethylene signal of the polymer assigned at 30.000 ppm.

[0221] c) Styrene Analyses

[0222] Atactic Polystyrene concentration was determined by a nuclearmagnetic resonance (N.M.R) method, and the total styrene contents wasdetermined by Fourier Transform Infrared spectroscopy (FTIR).

[0223] d) Low Temperature Impact

[0224] Samples were tested for low temperature impact strength by theinstrumented dart impact method (ASTM 3763-93). A Dynatup, Model 8000drop tower was used (General Research Corporation) with a drop height of12 inches and drop weight of 138.5 pounds. Specimens were unclamped andthe tup diameter was 0.625 inches, with an unsupported sample area of1.25 inches. Samples were conditioned in a freezer and removed to thetest setup, and tested after warming for 44 seconds to achieve −29° C.as determined by blank samples fitted with an internal thermocouple.Data acquisition and calculations were completed using the DYN730software system. Five samples were tested of each formulation and theresults averaged.

[0225] e) Conductivity

[0226] Injection and compression molded samples obtained in this workoften had different conductivity's on the surface compared to the coreand were therefore evaluated for both. This is especially true forblends in the ESD conductivity range.

[0227] “Surface conductivity” is a measurement of the bulk propertyobtained by traversing the surface of the injection or compressionmolded part and was obtained from a measurement of the resistancebetween the top and bottom of a sample which is approximately 3.175 mmthick. After conductive priming, the resistance was measured usinggraphite paper leads to increase contact surface area and to decreasethe contact resistance. The conductivity at the surface was measured bypainting a 1 cm² area of surface on both sides of the 3.2 mm thicktensile bar. The resistance from one surface of the bar to the other wasmeasured and the conductivity calculated. This is represented in FIG. 1.Three surface measurements were averaged from three different bars (ninemeasurements total) and the average of the values reported.

[0228] “Core conductivity” is a measurement of the bulk property withouttraversing the surface of the molded part and was calculated from theresistance in the longitudinal direction across a section of the barwhich had been exposed by cold fracturing at 77K. This is represented inFIG. 2.

[0229] In either case, the measurement surfaces were painted with aconductive carbon black primer (Type MPP4110, PPG Industries, Oak Creek,Wis.). The carbon black paint is recommended for polyolefns since it hasbeen formulated for good adhesion, while the silver paint can losecontact with the surface.

[0230] In either case, the conductivity was calculated from theresistance value, the area of the surface being tested, and the distancebetween the two measurement surfaces as follows:

σ=conductivity (S/cm)=Resistivity⁻¹ (ohm⁻¹.cm⁻¹) Resistivity=(measuredDC resistance in ohms)×(area “A” in cm²) (thichness “B” in cm)

[0231] The Individual Blend Components

[0232] a) “PP 1” is a polypropylene homopolymer available from the DowChemical Co., having an I₂ of 35 g/10 min (measured at 230° C.). “PP6331” is a polypropylene homopolymer available from Montell having an I₂of 12 grams/10 minutes (measured at 230° C.). “PP-44” is C705-44NApolypropylene having a melt flow of about 44 commercially produced byThe Dow Chemical Company.

[0233] b) “IP60” is an HDPE Dowlex IP60 commercially produced by The DowChemical Company, having an I₂ of 60 g/10 minute

[0234] c) ENGAGE™ 8180 is an ethylene/octene copolymer having a densityof 0.8630 g/cm³ and a melt index (I₂) of 0.50 g/10 min and iscommercially available from DuPont Dow Elastomers.

[0235] d) ENGAGE™ 8200 is an ethylene/octene copolymer having a densityof 0.8700 g/cm³ and a melt index (I₂) of 5.00 g/10 min and iscommercially available from DuPont Dow Elastomers.

[0236] e) STYRON™ 665 is a polystyrene having an I₂ of 1.5 g/10 minutes(measured at 200° C.) and available from The Dow Chemical Company.

[0237] f) STYRON™ 680 is a polystyrene having an I₂ of 10 g/10 minutes(measured at 200° C.) and available from The Dow Chemical Company.

[0238] g) “XE-2” is a conductive carbon black available as Degussa XE-2from the Degussa Corporation and having, a tapped density of 140 g/l , apH value of 8.5, and a DBP adsorption value of 380 ml/100 grams.

[0239] h) ESI #'s 1—??? were ethylene/styrene interpolymers and ESP #'s1-3 were ethylene/propylene/styrene interpolymers prepared using thefollowing catalysts, cocatalyst and polymerization procedure. Theprocess conditions for these samples are summarized in Table 1 and thepolymer properties are summarized in Table 2.

Catalyst(dimethyl[N-(1,1-dimethylethyl)-1,1-dimethyl-1-[((1,2,3,4,5-η)-1,5,6,7-tetrahydro-3-phenyl-s-indacen-1-yl]silanaminato(2-)-N]-titanium)Preparation Preparation of 3,5,6,7-Tetrahydro-s-Hydrindacen-1(2H)-one

[0240] Indan (94.00 g, 0.7954 moles) and 3-chloropropionyl chloride(100.99 g, 0.7954 moles) were stirred in CH₂Cl₂ (300 mL) at 0° C. asAlCl₃ (130.00 g, 0.9750 moles) was added slowly under a nitrogen flow.The mixture was then allowed to stir at room temperature for 2 hours.The volatiles were then removed. The mixture was then cooled to 0° C.and concentrated H₂SO₄ (500 mL) slowly added. The forming solid had tobe frequently broken up with a spatula as stirring was lost early inthis step. The mixture was then left under nitrogen overnight at roomtemperature. The mixture was then heated until the temperature readingsreached 90° C. These conditions were maintained for a 2 hour period oftime during which a spatula was periodically used to stir the mixture.After the reaction period crushed ice was placed in the mixture andmoved around. The mixture was then transferred to a beaker and washedintermittently with H₂O and diethylether and then the fractions filteredand combined. The mixture was washed with H₂O (2×200 mL). The organiclayer was then separated and the volatiles removed. The desired productwas then isolated via recrystallization from hexane at 0° C. as paleyellow crystals (22.36 g, 16.3% yield). ¹H NMR (CDCl₃): d2.04-2.19 (m, 2H), 2.65 (t, ³J_(HH)=5.7 Hz, 2 H), 2.84-3.0 (m, 4 H), 3.03 (t,³J_(HH)=5.5 Hz, 2 H), 7.26 (s, 1 H), 7.53 (s, 1 H). ¹³C NMR (CDCl₃):d25.71, 26.01, 32.19, 33.24, 36.93, 118.90, 122.16, 135.88, 144.06,152.89, 154.36, 206.50. GC-MS: Calculated for C₁₂H₁₂O 172.09, found172.05.

Preparation of 1,2,3,5-Tetrahydro-7-phenyl-s-indacen

[0241] 3,5,6,7-Tetrahydro-s-Hydrindacen-1(2H)-one (12.00 g, 0.06967moles) was stirred in diethylether (200 mL) at 0° C. as PhMgBr (0.105moles, 35.00 mL of 3.0 M solution in diethylether) was added slowly.This mixture was then allowed to stir overnight at room temperature.After the reaction period the mixture was quenched by pouring over ice.The mixture was then acidified (pH=1) with HCl and stirred vigorouslyfor 2 hours. The organic layer was then separated and washed with H₂O(2×100 mL) and then dried over MgSO₄. Filtration followed by the removalof the volatiles resulted in the isolation of the desired product as adark oil (14.68 g, 90.3% yield). ¹H NMR (CDCl₃): d2.0-2.2 (m, 2 H),2.8-3.1 (m, 4 H), 6.54 (s, 1H), 7.2-7.6 (m, 7 H). GC-MS: Calculated forC₁₈H₁₆ 232.13, found 232.05.

Preparation of 1,2,3,5-Tetrahydro-7-phenyl-s-indacene, dilithium salt

[0242] 1,2,3,5-Tetrahydro-7-phenyl-s-indacen (14.68 g, 0.06291 moles)was stirred in hexane (150 mL) as nBuLi (0.080 moles, 40.00 mL of 2.0 Msolution in cyclohexane) was slowly added. This mixture was then allowedto stir overnight. After the reaction period the solid was collected viasuction filtration as a yellow solid which was washed with hexane, driedunder vacuum, and used without further purification or analysis (12.2075g, 81.1% yield).

Preparation ofChlorodimethyl(1,5,6,7-tetrahydro-3-phenyl-s-indacen-1-yl)silane

[0243] 1,2,3,5-Tetrahydro-7-phenyl-s-indacene, dilithium salt (12.2075g, 0.05102 moles) in THF (50 mL) was added dropwise to a solution ofMe₂SiCl₂ (19.5010 g, 0.1511 moles) in THF (100 mL) at 0° C. This mixturewas then allowed to stir at room temperature overnight. After thereaction period the volatiles were removed and the residue extracted andfiltered using hexane. The removal of the hexane resulted in theisolation of the desired product as a yellow oil (15.1492 g, 91.1%yield). ¹H NMR (CDCl₃): d0.33 (s, 3 H), 0.38 (s, 3 H), 2.20 (p,³J_(HH)=7.5 Hz, 2 H), 2.9-3.1 (m, 4 H), 3.84 (s, 1 H), 6.69 (d,³J_(HH)=2.8 Hz, 1 H), 7.3-7.6 (m, 7 H), 7.68 (d, ³J_(HH)=7.4 Hz, 2 H).¹³C NMR (CDCl₃): d0.24, 0.38, 26.28, 33.05, 33.18, 46.13, 116.42,119.71, 127.51, 128.33, 128.64, 129.56, 136.51, 141.31, 141.86, 142.17,142.41, 144.62. GC-MS: Calculated for C₂₀H₂₁ClSi 324.11, found 324.05.

Preparation ofN-(1,1-Dimethylethyl)-1,1-dimethyl-1-(1,5,6,7-tetrahydro-3-phenyl-s-indacen-1-yl)silanamine

[0244] Chlorodimethyl(1,5,6,7-tetrahydro-3-phenyl-s-indacen-1-yl)silane(10.8277 g, 0.03322 moles) was stirred in hexane (150 mL) as NEt₃(3.5123 g, 0.03471 moles) and t-butylamine (2.6074 g, 0.03565 moles)were added. This mixture was allowed to stir for 24 hours. After thereaction period the mixture was filtered and the volatiles removedresulting in the isolation of the desired product as a thick red-yellowoil (10.6551 g, 88.7% yield). ¹H NMR (CDCl₃): d0.02 (s, 3 H), 0.04 (s, 3H), 1.27 (s, 9 H), 2.16 (p, ³J_(HH)=7.2 Hz, 2 H), 2.9-3.0 (m, 4 H), 3.68(s, 1 H), 6.69 (s, 1 H), 7.3-7.5 (m, 4 H), 7.63 (d, ³J_(HH)=7.4 Hz, 2H). ¹³C NMR (CDCl₃): d-0.32, −0.09, 26.28, 33.39, 34.11, 46.46, 47.54,49.81, 115.80, 119.30, 126.92, 127.89, 128.46, 132.99, 137.30, 140.20,140.81, 141.64, 142.08, 144.83.

Preparation ofN-(1,1-Dimethylethyl)-1,1-dimethyl-1-(1,5,6,7-tetrahydro-3-phenyl-s-indacen-1-yl)silanamine,dilithium salt

[0245]N-(1,1-Dimethylethyl)-1,1-dimethyl-1-(1,5,6,7-tetrahydro-3-phenyl-s-indacen-1-yl)silanamine(10.6551 g, 0.02947 moles) was stirred in hexane (100 mL) as nBuLi(0.070 moles, 35.00 mL of 2.0 M solution in cyclohexane) was addedslowly. This mixture was then allowed to stir overnight during whichtime no salts crashed out of the dark red solution. After the reactionperiod the volatiles were removed and the residue quickly washed withhexane (2×50 mL). The dark red residue was then pumped dry and usedwithout further purification or analysis (9.6517 g, 87.7% yield).

Preparation ofDichloro[N-(1,1-dimethylethyl)-1,1-dimethyl-1-[(1,2,3,4,5-η)-1,5,6,7-tetrahydro-3-phenyl-s-indacen-1-yl]silanaminato(2-)-N]titanium

[0246]N-(1,1-Dimethylethyl)-1,1-dimethyl-1-(1,5,6,7-tetrahydro-3-phenyl-s-indacen-1-yl)silanamine,dilithium salt (4.5355 g, 0.01214 moles) in THF (50 mL) was addeddropwise to a slurry of TiCl₃(THF)₃ (4.5005 g, 0.01214 moles) in THF(100 mL). This mixture was allowed to stir for 2 hours. PbCl₂ (1.7136 g,0.006162 moles) was then added and the mixture allowed to stir for anadditional hour. After the reaction period the volatiles were removedand the residue extracted and filtered using toluene. Removal of thetoluene resulted in the isolation of a dark residue. This residue wasthen slurried in hexane and cooled to 0° C. The desired product was thenisolated via filtration as a red-brown crystalline solid (2.5280 g,43.5% yield). ¹H NMR (CDCl₃): d0.71 (s, 3 H), 0.97 (s, 3 H), 1.37 (s, 9H), 2.0-2.2 (m, 2 H), 2.9-3.2 (m, 4 H), 6.62 (s, 1 H), 7.35-7.45 (m, 1H), 7.50 (t, ³J_(HH)=7.8 Hz, 2 H), 7.57 (s, 1 H), 7.70 (d, ³J_(HH)=7.1Hz, 2 H), 7.78 (s, 1 H). ¹H NMR (C₆D₆): d0.44 (s, 3 H), 0.68 (s, 3 H),1.35 (s, 9 H), 1.6-1.9 (m, 2 H), 2.5-3.9 (m, 4 H), 6.65 (s, 1 H),7.1-7.2 (m, 1 H), 7.24 (t, ³J_(HH)=7.1 Hz, 2 H), 7.61 (s, 1 H), 7.69 (s,1 H), 7.77-7.8 (m, 2 H). ¹³C NMR (CDCl₃): d1.29, 3.89, 26.47, 32.62,32.84, 32.92, 63.16, 98.25, 118.70, 121.75, 125.62, 128.46, 128.55,128.79, 129.01, 134.11, 134.53, 136.04, 146.15, 148.93. ¹³C NMR (C₆D₆):d0.90, 3.57, 26.46, 32.56, 32.78, 62.88, 98.14, 119.19, 121.97, 125.84,127.15, 128.83, 129.03, 129.55, 134.57, 135.04, 136.41, 136.51, 147.24,148.96.

Preparation ofDimethyl[N-(1,1-dimethylethyl)-1,1-dimethyl-1-[(1,2,3,4,5-η)-1,5,6,7-tetrahydro-3-phenyl-s-indacen-1-yl]silanaminato(2-)-N]titanium

[0247]Dichloro[N-(1,1-dimethylethyl)-1,1-dimethyl-1-[(1,2,3,4,5-η)-1,5,6,7-tetrahydro-3-phenyl-s-indacen-1-yl]silanaminato(2-)-N]titanium(0.4970 g, 0.001039 moles) was stirred in diethylether (50 mL) as MeMgBr(0.0021 moles, 0.70 mL of 3.0 M solution in diethylether) was addedslowly. This mixture was then stirred for 1 hour. After the reactionperiod the volatiles were removed and the residue extracted and filteredusing hexane. Removal of the hexane resulted in the isolation of thedesired product as a golden yellow solid (0.4546 g, 66.7% yield). ¹H NMR(C₆D₆): d0.071 (s, 3 H), 0.49 (s, 3 H), 0.70 (s, 3 H), 0.73 (s, 3 H),1.49 (s, 9 H), 1.7-1.8 (m, 2 H), 2.5-2.8 (m, 4 H), 6.41 (s, 1 H), 7.29(t, ³J_(HH)=7.4 Hz, 2 H), 7.48 (s, 1 H), 7.72 (d, ³J_(HH)=7.4 Hz, 2 H),7.92 (s, 1 H). ¹³C NMR (C₆D₆): d2.19, 4.61, 27.12, 32.86, 33.00, 34.73,58.68, 58.82, 118.62, 121.98, 124.26, 127.32, 128.63, 128.98, 131.23,134.39, 136.38, 143.19, 144.85.

Preparation of Catalyst B:(1H-cyclopenta[1]phenanthrene-2-yl)dimethyl(t-butylamido)-silanetitanium1,4-dilphenalbutadiene)

[0248] 1) Preparation of lithium 1H-cyclopenta[1]phenanthrene-2-yl

[0249] To a 250 ml round bottom flask containing 1.42 g (0.00657 mole)of 1H-cyclopenta[1]phenanthrene and 120 ml of benzene was addeddropwise, 4.2 ml of a 1.60 M solution of n-BuLi in mixed hexanes. Thesolution was allowed to stir overnight. The lithium salt was isolated byfiltration, washing twice with 25 ml benzene and drying under vacuum.Isolated yield was 1.426 g (97.7 percent). 1H NMR analysis indicated thepredominant isomer was substituted at the 2 position.

[0250] 2) Preparation of(1H-cyclopenta[1]phenanthrene-2-yl)dimethylchlorosilane

[0251] To a 500 ml round bottom flask containing 4.16 g (0.0322 mole) ofdimethyldichlorosilane (Me₂SiCl₂) and 250 ml of tetrahydrofuran (THF)was added dropwise a solution of 1.45 g (0.0064 mole) of lithium1H-cyclopenta[1]phenanthrene-2-yl in THF. The solution was stirred forapproximately 16 hours, after which the solvent was removed underreduced pressure, leaving an oily solid which was extracted withtoluene, filtered through diatomaceous earth filter aid (Celite™),washed twice with toluene and dried under reduced pressure. Isolatedyield was 1.98 g (99.5 percent).

[0252] 3) Preparation of(1H-cyclopenta[1]phenanthrene-2-yl)dimethyl(t-butylamino)silane

[0253] To a 500 ml round bottom flask containing 1.98 g (0.0064 mole) of(1H-cyclopenta[1]phenanthrene-2-yl)dimethylchlorosilane and 250 ml ofhexane was added 2.00 ml (0.0160 mole) of t-butylamine. The reactionmixture was allowed to stir for several days, then filtered usingdiatomaceous earth filter aid (Celite™), washed twice with hexane. Theproduct was isolated by removing residual solvent under reducedpressure. The isolated yield was 1.98 g (88.9 percent).

[0254] 4) Preparation of dilithio(1H-cyclopenta[1]phenanthrene-2-yl)dimethyl(t-butylamido)silane

[0255] To a 250 ml round bottom flask containing 1.03 g (0.0030 mole) of(1H-cyclopenta[1]phenanthrene-2-yl)dimethyl(t-butylamino)silane) and 120ml of benzene was added dropwise 3.90 ml of a solution of 1.6 M n-BuLiin mixed hexanes. The reaction mixture was stirred for approximately 16hours. The product was isolated by filtration, washed twice with benzeneand dried under reduced pressure. Isolated yield was 1.08 g (100percent).

[0256] 5) Preparation of(1H-cyclopenta[1]phenanthrene-2-yl)dimethyl(t-butylamido)silanetitaniumdichloride

[0257] To a 250 ml round bottom flask containing 1.17 g (0.0030 mole) ofTiCl₃.3THF and about 120 ml of THF was added at a fast drip rate about50 ml of a THF solution of 1.08 g of dilithio(1H-cyclopenta[1]phenanthrene-2-yl)dimethyl(t-butylamido)silane. Themixture was stirred at about 20° C. for 1.5 h at which time 0.55 gm(0.002 mole) of solid PbCl₂ was added. After stirring for an additional1.5 h the THF was removed under vacuum and the reside was extracted withtoluene, filtered and dried under reduced pressure to give an orangesolid. Yield was 1.31 g (93.5 percent).

[0258] 6) Preparation of(1H-cyclopenta[1]phenanthrene-2-yl)dimethyl(t-butylamido)silanetitanium1,4-diphenylbutadiene

[0259] To a slurry of(1H-cyclopenta[1]phenanthrene-2-yl)dimethyl(t-butylamido)silanetitaniumdichloride (3.48 g, 0.0075 mole) and 1.551 gm (0.0075 mole) of1,4-diphenyllbutadiene in about 80 ml of toluene at 70° C. was add 9.9ml of a 1.6 M solution of n-BuLi (0.0150 mole). The solution immediatelydarkened. The temperature was increased to bring the mixture to refluxand the mixture was maintained at that temperature for 2 hrs. Themixture was cooled to about −20° C. and the volatiles were removed underreduced pressure. The residue was slurried in 60 ml of mixed hexanes atabout 20° C. for approximately 16 hours. The mixture was cooled to about−25° C. for about 1 h. The solids were collected on a glass frit byvacuum filtration and dried under reduced pressure. The dried solid wasplaced in a glass fiber thimble and solid extracted continuously withhexanes using a soxhlet extractor. After 6 h a crystalline solid wasobserved in the boiling pot. The mixture was cooled to about −20° C.,isolated by filtration from the cold mixture and dried under reducedpressure to give 1.62 g of a dark crystalline solid. The filtrate wasdiscarded. The solids in the extractor were stirred and the extractioncontinued with an additional quantity of mixed hexanes to give anadditional 0.46 gm of the desired product as a dark crystalline solid.

Cocatalyst (bis(hydrogenated-tallowalkyl)methylamine) (B-FABA)Preparation

[0260] Methylcyclohexane (1200 mL) was placed in a 2 L cylindricalflask. While stirring, bis(hydrogenated-tallowalkyl)methylamine (ARMEEN®M2HT, 104 g, ground to a granular form) was added to the flask andstirred until completely dissolved. Aqueous HCl (1M, 200 mL) was addedto the flask, and the mixture was stirred for 30 minutes. A whiteprecipitate formed immediately. At the end of this time,LiB(C₆F₅)₄.Et₂O.3 LiCl (Mw=887.3; 177.4 g) was added to the flask. Thesolution began to turn milky white. The flask was equipped with a 6″Vigreux column topped with a distillation apparatus and the mixture washeated (140° C. external wall temperature). A mixture of ether andmethylcyclohexane was distilled from the flask. The two-phase solutionwas now only slightly hazy. The mixture was allowed to cool to roomtemperature, and the contents were placed in a 4 L separatory funnel.The aqueous layer was removed and discarded, and the organic layer waswashed twice with H₂O and the aqueous layers again discarded. The H₂Osaturated methylcyclohexane solutions were measured to contain 0.48 wtpercent diethyl ether (Et₂O).

[0261] The solution (600 mL) was transferred into a 1 L flask, spargedthoroughly with nitrogen, and transferred into the drybox. The solutionwas passed through a column (1″ diameter, 6″ height) containing13×molecular sieves. This reduced the level of Et₂O from 0.48 wt percentto 0.28 wt percent. The material was then stirred over fresh 13×sieves(20 g) for four hours. The Et₂O level was then measured to be 0.19 wtpercent. The mixture was then stirred overnight, resulting in a furtherreduction in Et₂O level to approximately 40 ppm. The mixture wasfiltered using a funnel equipped with a glass frit having a pore size of10-15 μm to give a clear solution (the molecular sieves were rinsed withadditional dry methylcyclohexane). The concentration was measured bygravimetric analysis yielding a value of 16.7 wt percent.

[0262] Polymerization

[0263] The interpolymers were prepared in a 6 gallon (22.7 L), oiljacketed, Autoclave continuously stirred tank reactor (CSTR). Amagnetically coupled agitator with Lightning A-320 impellers providedthe mixing. The reactor ran liquid full at 475 psig (3,275 kPa). Processflow was in at the bottom and out of the top. A heat transfer oil wascirculated through the jacket of the reactor to remove some of the heatof reaction. At the exit of the reactor was a micromotion flow meterthat measured flow and solution density. All lines on the exit of thereactor were traced with 50 psi (344.7 kPa) steam and insulated.

[0264] Ethylbenzene solvent was supplied to the reactor at 30 psig (207kPa). The feed to the reactor was measured by a Micro-Motion mass flowmeter. A variable speed diaphragm pump controlled the feed rate. At thedischarge of the solvent pump, a side stream was taken to provide flushflows for the catalyst injection line (1 lb/hr (0.45 kg/hr)) and thereactor agitator (0.75 lb/hr (0.34 kg/hr)). These flows were measured bydifferential pressure flow meters and controlled by manual adjustment ofmicro-flow needle valves. Uninhibited styrene monomer was supplied tothe reactor at 30 psig (207 kpa). The feed to the reactor was measuredby a Micro-Motion mass flow meter. A variable speed diaphragm pumpcontrolled the feed rate. The styrene streams was mixed with theremaining solvent stream. Ethylene was supplied to the reactor at 600psig (4,137 kPa). The ethylene stream was measured by a Micro-Motionmass flow meter just prior to the Research valve controlling flow. ABrooks flow meter/controller was used to deliver hydrogen into theethylene stream at the outlet of the ethylene control valve. Theethylene/hydrogen mixture combines with the solvent/styrene stream atambient temperature. The temperature of the solvent/monomer as it entersthe reactor was dropped to ˜5° C. by an exchanger with −5° C. glycol onthe jacket. This stream entered the bottom of the reactor. The threecomponent catalyst system and its solvent flush also entered the reactorat the bottom but through a different port than the monomer stream.Preparation of the catalyst components took place in an inert atmosphereglove box. The diluted components were put in nitrogen padded cylindersand charged to the catalyst run tanks in the process area. From theserun tanks the catalyst was pressured up with piston pumps and the flowwas measured with Micro-Motion mass flow meters. These streams combinewith each other and the catalyst flush solvent just prior to entrythrough a single injection line into the reactor.

[0265] Polymerization was stopped with the addition of catalyst kill(water mixed with solvent) into the reactor product line after themicromotion flow meter measuring the solution density. Other polymeradditives can be added with the catalyst kill. A static mixer in theline provided dispersion of the catalyst kill and additives in thereactor effluent stream. This stream next entered post reactor heatersthat provide additional energy for the solvent removal flash. This flashoccurred as the effluent exited the post reactor heater and the pressurewas dropped from 475 psig (3,275 kPa) down to ˜250 mm of pressureabsolute at the reactor pressure control valve. This flashed polymerentered a hot oil jacketed devolatilizer. Approximately 85 percent ofthe volatiles were removed from the polymer in the devolatilizer. Thevolatiles exited the top of the devolatilizer. The stream was condensedwith a glycol jacketed exchanger and entered the suction of a vacuumpump and was discharged to a glycol jacket solvent and styrene/ethyleneseparation vessel. Solvent and styrene were removed from the bottom ofthe vessel and ethylene from the top. The ethylene stream was measuredwith a Micro-Motion mass flow meter and analyzed for composition. Themeasurement of vented ethylene plus a calculation of the dissolvedgasses in the solvent/styrene stream were used to calculate the ethyleneconversion. The polymer seperated in the devolatilizer was pumped outwith a gear pump to a ZSK-30 devolatilizing vacuum extruder. The drypolymer exits the extruder as a single strand. This strand was cooled asit was pulled through a water bath. The excess water was blown from thestrand with air and the strand was chopped into pellets with a strandchopper.

[0266] The various catalysts, co-catalysts and process conditions usedto prepare the various individual ethylene styrene interpolymers for usein the blend compositions of the present invention are summarized inTable 1. TABLE 1 Process Conditions For Preparation Of Individual BlendComponents Reactor Solvent Ethylene Hydrogen Styrene Propylene C2 TempFlow Flow Flow Flow Flow Conversion Co- B/Ti MMAO^(e/) Sample # ° C.lb/hr(kg/hr) lb/hr(kg/hr) lb/hr(kg/hr) lb/hr(kg/hr lb/hr(kg/hr) %Catalyst Catalyst Ratio TiRatio ESI #1 73.4 13.5(6.1) 1.2(0.5)   9(4.1)12.0(5.4) — 87.3 a B-FABA 1.3 10 ES1 #2 101.4 19.2(8.7) 2.0(0.9)  4(1.8)  7.0(3.2) — 86.5 b B-FABA 1.3 10 ESI #3 99.2 45.0(20.4)4.3(1.9)   20(9.0)  5.0(2.3) — 96.6 a FAB^(c) 3.5  3.5 ESI #4 84.328.3(12.8) 2.3(1.0) 15.9(7.2) 10.5(4.8) — 92.2 a B-FABA 1.2 10 ESI #592.2 37.0(16.8) 2.8(1.3) 25.3(11.5)  8.0(3.6) — 96.5 a FAB^(c) 3.5  3.5ESI #6 82.2 37.0(16.8) 1.9(0.9)   4(1.8)   70(31.7) — 96.6 a FAB^(c) 3.5 3.5 ESI #7 101.4 36.0(16.3) 3.9(1.8)   35(15.8)  2.9(1.3) — 95.9 aFAB^(c) 3.5  3.0 ESI #8 80.7 37.0(16.8) 1.9(0.9)   35(15.8)  6.5(2.9) —95.2 a FAB^(c) 3.5  3.5 ESI #9 79.3 41.0(18.6) 2.2(1.0)   26(11.8) 210(95.1) — 96.9 a FAB^(c) 3.5  6 ESI #10 92.1 32.0(14.5) 2.8(1.3) 5.0(2.3)  5.0(2.3) — 96.9 a FAB^(c) 3.5  3.5 ESI #11 88.8 37.0(16.8)2.8(1.3) 30.0(13.6)  8.5(3.8) — 96 2 a FAB^(c) 3.5  3.5 ESI #12 82.337.0(16.8) 1.9(0.9)  3.8(1.8)  7.0(3.2) — 96.6 a FAB^(c) 3.5  3.5 ESI#13 99.0 45.0(20.4) 4.3(1.9) 21.0(9.5)  5.0(2.3) — 96.6 a FAB^(c) 3.5 3.5 ESI #14 91.5 38.6(17.5) 3.1(1.4) 14.5(6.6)  6.5(2.9) — 96.8 aFAB^(c) 3.0 7 0 ESI #15 79.8 37.0(16.8) 1.9(0.9) 25.0(11.3)  7.0(3.2) —96 3 a FAB^(c) 3.5  3.5 ESI #16 103.1 36.0(16.3) 3.9(1.8) 22.0(10.0) 2.9(1.3) — 95.8 a FAB^(c) 3.5  3.0 ESI #17 76.9 30.0(13.6) 1.3(0.6) 5.0(2.3) 10.0(4.5) — 99.0 a FAB^(c) 2.8 4 0 ESI #18 100.7 35.0(15.8)4.0(1.8) 10.0(4.5)  3.7(1.7) — 91.1 f FAB^(c) 3.0  5.0 ESI #19 85.035.0(15.8) 2.8(1.3) 10.0(4.5)  6.3(2.8) — 91.8 f FAB^(c) 3.0  5.0 ESI#20 70.0 30.0(13.6) 1.3(0.6)  1.0(0.4) 11.5(5.2) — 95.7 a FAB^(c) 3.0 4.0 ESI #21 102.0   36(16.3) 3.9(1.8) 25.5(1.5)  2.8(1.3) 96.0 aFAB^(c) 3 0  6.0 ESP #1 68.8 14.0(6.3) 1.2(0.5) 18.0(8.1)  5.0(2.3)1.2(0.5) 83.5 b FAB^(c) 4.6  1.7 ESP #2 63.3 11.0(5.0) 1.2(0.5)19.0(8.6)  8.0(3.6) 0.8(0.4) 73.9 b FAB^(c) 4.0  8.0 ESP #3 60.9 7.0(3.2) 1.2(0.5) 16.0(7.2) 12.0(5.4) 0.4(0.2) 75.9 b FAB^(c) 3.0  8.0

[0267] TABLE 2 Properties of Individual Blend Components InterpolymerGottfert Viscosity wt % mol % (wt %) wt % Component A (cm³/10 m) aPSstyrene propylene ESI #1 1.16 <10 36.6 (68.2) 0 ESI #2 1.12 6.5  9.7(28.5) 0 ESI #3 1.51 0.25 10.5 (30.3) 0 ESI #4 1.09 2.00 23.9 (53.9) 0ESI #5 1.11 0.80 19.0 (46.6) 0 ESI #6 1.10 0.80 27.8 (58.8) 0 ESI #710.80 0.15  6.8 (21.3) 0 ESI #8 19.05 0.90 24.2 (54.2) 0 ESI #9 10.932.80 43.4 (74)   0 ESI #10 1.65 8.12 16.9 (43.1) 0 ESI #11 2.73 8.3023.3 (53)   0 ESI #12 1.00 0.60 27.9 (59)   0 ESI #13 1.60 8.55 11.1(31.7) 0 ESI #14 1.4 0.6 18.1 (45.1) 0 ESI #15 11.2 .75 31.4 (63)   0ESI #16 1.2 .1  7.0 (21.9) 0 ESI #17 9 4.2 52.0 (80.1) 0 ESI #18 1.1 1.012.0 (33.7) 0 ESI #19 2.9 2.1 24.6 (54.8) 0 ESI #20 1.2 6.4 47.8 (77.3)0 ESI #21 8.0 0.1  7.0 (21.9) 0 EPS #1 1.90 2.3 (27.0) 33.0 EPS #2 1.879.3 (37.0) 23.0 EPS #3 1.04 26.6 (47.0) 13.0

[0268] Processing

[0269] Mixing of the blends was done on a Haake RC-90 torque rheometerequipped with a Rheomix 3000 (Haake) mixing bowl with standard rollerblades. The sample mixing capacity was approximately 200 grams. Toobtain enough material for injection molding, duplicate mixing runs weremade for each formulation. Mixing data for each run was stored as a datafile. Compression molding required less material and required only oneHaake blending batch of material.

[0270] The mixed carbon-filled or other conductive additive-filledpolymer samples to were ground in a Wiley mill (Model 4, ThomasScientific) after being cooled in liquid nitrogen. The ground sampleswere vacuum dried overnight just prior to molding. Injection molding wasdone in a Boy 30M molding machine with a barrel temperature of 200° C.,nozzle temperature of 210° C., and mold temperature of 45° C. Moldinginjection pressure was typically 500 psi, and hold pressure was 550 psi.Overall cycle time was 40 seconds. Molded samples consisted of onetensile bar and one disk for impact testing per shot. Typically, thefirst 6 shots were discarded and the next 10 or more collected as samplequantity allowed. Compression molding was done on a Carver hydraulicpress with the platens heated to 195° C.+/−5° C. The platen pressure wastypically 5000 psig and was held for approximately 4 minutes. Onceremoved from the press, the molding set-up was placed in dry ice toquickly cool the sample for easy removal from the mold. Molded sampleswere 6.25 cm×1.25 cm bars.

[0271] Many examples below are formulations of rubber modifiedpolypropylenes which have been melt processed, injection molded, andthen tested for conductivity, low temperature impact (LTI) and meltviscosity (MFR). In general it is best to have high values for all ofthese. A commercial threshold value for LTI in a TPO fascia orinstrument panel would be about 30 ft-lb.

[0272] Table 3 shows that the presence of both EPS and ESI enhances theconductivity of the core of a blend sample and also brings theconductivity to the surface of a composite which would otherwise besurface insulating. The property of surface conductivity is beneficialbecause it allows facile grounding of the part. TABLE 3 ESI and EPSpolymers as an additive in PP ESI Other Polymer Degussa XE-2 Core Surf.(Component A) Component C Component B Cond^(a) Cond.^(a) LTI Blend Ex #Type (wt %) Type (wt %) wt % (S/cm) (S/cm) (ft-lb) MFR Comp. none,  0IP60  7% 6 3E−5 OL 43.0 3.8 Ex 1 PP 1 52% EG8180 35% Ex 1 EPS #1 35 IP60 7% 6 2E−4 2E−5 0.3 6.2 PP 1 52% Ex. 2 EPS #2 35 IP60  7% 6 1E−4 2E−50.5 6.0 PP 1 52% Ex. 3 EPS #3 35 IP60  7% 6 7E−5 9E−5 0.1 4.7 PP H70252% Ex. 4 ESI #1 35 IP60  7% 6 2E−4 7E−5 0.1 5.4 PP 1 52% Ex 5 ESI #2 35IP60  7% 6 2E−4 4E−5 0.2 4.8 PP 1 52%

[0273] Table 4 shows that in rubber modified polypropylene compositeswhich are formulated to include EG8180 (impact rubber modifier) the LTIcan be maintained while adding surface conductivity. At equal conductivecarbon concentrations the ESI-containing rubber modified polypropyleneis somewhat more conductive at the core, and significantly moreconductive at the surface. This unexpected result occurs with as littleas 10% wt. of ESI in the formulation. TABLE 4 Use of PS, ESI and EPS inTPO ESI Other Polymer Degussa XE-2 Core Surf. (Component A) (ComponentC) (Component B) Cond Cond LTI Blend Ex # type wt % type wt % wt %(S/cm)^(a) (S/cm)^(a) (ft-lb) MFR Comp none  0 IP60  7 5 3E−6 OL 40.04.8 Ex 2 EG 8180 35 PP 1 53 Comp none  0 IP60  7 6 3E−5 OL 43.0 4.5 Ex 3EG 8180 35 PP 1 52 Ex 6 ESI #3 10 IP60  7 4 6E−7 OL 44.8 6.1 EG 8180 26PP 1 53 Ex 7 ESI #3 10 IP60  7 5 1E−5 OL 44.2 4.6 EG 8180 25 PP 1 53 Ex8 ESI #2 13 EG 8180 29 6 6E−6 OL 45.3 2.8 PP 1 52 Ex 9 ESI #1 10 IP60  76 8E−5 2E−5 31.1 3.6 EG 8180 25 PP 1 52 Ex 10 ESI #2 10 IP60  7 6 9E−52E−8 46.5 3.7 EG 8180 25 PP 1 52 Ex 11 EPS #1 10 IP60  7 6 9E−6 4E−643.2 4.0 EG 8180 25 PP 1 52 Ex 12 EPS #3 10 IP60  7 6 3E−5 2E−6 24.4 3.5EG 8180 25 PP 1 52 Ex 13 EPS #1 13 EG 8180 29 6 8E−6 2E−7 46.4 3 PP 1 52Ex 14 EPS #2 13 EG 8180 29 6 1E−5 5E−8 45.8 3.1 PP 1 52 Ex 15 EPS #3 13EG 8180 29 6 2E−5 OL 45.6 2.9 PP 1 52

[0274] Table 5 shows that there is an improvement in conductivity withESI for polypropylene based formulations having EG8200 as the impactmodifier. TABLE 5 Use of ESI in Conductive Thermoplastic Polyolefins ESIOther Polymer Degussa XE-2 Core Surf. Component A Component C ComponentB Cond Cond LTI Blend ID Type Wt % Type Wt % Wt % (S/cm)^(a) (S/cm)^(a)(ft-lb) MFR Ex 16 ESI #3 10 IP60  7 4 1E−6 OL 43.2 10.6 EG8200 26 PP1 53Ex 17 ESI #3 10 IP60  7 5 2E−5 OL 19.8 8.3 EG8200 25 PP1 53 Ex 18 ESI #310 IP60  7 6 7E−5 6E−8 11.7 7.6 EG8200 25 PP1 52 Comp none  0 IP60  7 42E−6 OL 42.8 11.8 Ex 4 EG8200 35 PP1 54 Comp none  0 IP60  7 5 2E−5 OL42.1 9 6 Ex 5 EG8200 35 PP1 53

[0275] Table 6 shows that ESI added to several different host polymersimproves the conductivity at constant conductive carbon loading, incomparison to the Comparative Experiment # made without ESI. TABLE 6 ESIAs An Additive To Semiconducting Conductive Carbon Loaded Polymers ESIconductiv- Component A Degussa XE-2 ity Other Polymer wt % Component B @core Ex # Component C Type Styrene wt % (s/cm)^(a) Comp PPI —  0 21.1E−6 Ex 6 Ex 19 ESI #13 25% 2 1.1E−4 Ex 20 ESI #12 25% 2 1.8E−8 CompEG 8180 —  0 2 OL Ex 7 Ex 21 ESI #13 25% 2 OL Ex 22 ESI #12 25% 2 OLComp Styron 665 —  0 2 OL Ex 8 Ex 23 ESI #13 25% 2 7.2E−8 Ex 24 ESI #1225% 2 OL Comp Styron 680 —  0 2 2.9E−8 Ex 9 Ex 25 ESI #13 25% 2 6.8E−8Ex 26 ESI #12 25% 2 3.7E−8

[0276] The balance of physical properties and conductivity is animportant feature of the present invention. Polypropylenes (PP),polystyrenes (PS), ethylene styrene interpolymers (ESI), and ethylenepropylene styrene interpolymers (EPS) all have similar percolationbehavior (the development of conductivity as a function of conductiveadditive loading level). That is, when loaded with the same amount ofconductive additive they exhibit similar conductivities. However, atsimilar loading levels of conductive additive, PP and PS are morebrittle than ESI and EPS as measured by, for example, flex modulus. Thebalance of physical properties is different when comparing ESI and EPSto, for example, ethylene/alpha olefin copolymers (AOC). The flexibilityof conductive carbon loaded AOC, ESI and EPS are similar at similarconductive carbon loading levels. However, the amount of conductivecarbon required to achieve the same conductivity differs, AOC requiresmore conductive carbon than does ESI or EPS.

[0277] Table 7 below shows the conductivity of various polymers atseveral loadings of conductive Degussa XE-2 carbon. From this it can beseen that ES and EPS interpolymers have conductivity which is similar toPS and significantly higher than polyolefins, especially EO rubbers,e.g. EG8180, when modified to be semiconducting.

[0278] The good percolation behavior exhibited when the primarilyamorphous interpolymers are a component of the blends of the presentinvention is unexpected. Semiconductivity is enhanced by crystallinityin a given polymer. Thus PP, a polymer having significant crystallinity,exhibits semiconductivity when loaded with an appropriate amount ofconductive additive. In comparison Engage™ rubbers which are amorphousexhibit poor conductivity when loaded with an equivalent amount ofconductive additive. TABLE 7 Conductivity of Individual Blend Componentsvs Degussa XE-2 Loading Example # Polymer Degussa XE-2 wt % conductivity(S/cm)^(a) Comp Ex Engage 8180 10 4E-7 10 20 9.1E-2 30 0.55 Comp ExProfax ™ 6331 10 2E-2 11 Comp Ex Styron ™ 665 10 2E-3 12 Comp ExStyron ™ 680 10 2E-4 13 Ex 27 EPS #1 10 3E-3 Ex 28 EPS #2 10 2E-2 Ex 29EPS #3 10 2E-2 Ex 30 ESI #2 10 3E-3 Ex 31 ESI #4 10 6E-3 Ex 32 ESI #1 102E-2 Ex 33 ESI #13 30 0.47 Ex 34 ESI #5 30 0.45 Ex 35 ESI #11 30 0.52 Ex36 ESI #12 30 0.64 Ex 37 ESI #3 10 1E-8 Ex 38 ESI #5 10 1E-5 Ex 39 ESI#6 10 1E-3

[0279] TABLE 8 Second Conductivity* 6 ESI #16 ESI wt % Degussa w % (mol%) Melt wt % in wt % (mol %) Melt wt % in XE2 Ex # styrene Index, G#blend styrene (ESI #) Index, G# blend (S/cm) 40 22.0 (7.1) 1.2 94  04.5E−6 41 80.0 (51.8) 10.0 94 7.8E−3 (ESI #20) 42 22.0 (7.1) 1.2 75 80.0(51.8) 10.0 19 2.5E−4 (1.5E−3) (ESI #20) 43 63.0 (31.4) 11.2 94 8.8E−5(ESI #15) 44 22.0 (7.1) 1.2 75 63.0 (31.4) 11.2 19 1.4E−3 (2.0E−5) (ESI#15) 45 55.0 (24.8) 2.9 94 1.3E−6 (ESI #19) 46 22.0 (7.1) 1.2 75 55.0(24.8) 2.9 19 1.8E−4 (3.6E−6) (ESI #19) 47 45.0 (18.0) 1.4 94 2.3E−8(ESI #14) 48 22.0 (7.1) 1.2 75 45.0 (18.0) 1.4 19 3.6E−4 (3.4E−6) (ESI#14) 49 34.0 (12.2) ESI 1.1 94 3.2E−7 #18) 50 22.0 (7.1) 1.2 75 34.0(12.2) 1.1 19 9.2E−5 (3.4E−6) (ESI #18)

[0280] Compression molding was done on a Carver Model 2697 Press at10,000 psi for 3 minutes at 385° F. These results show that, generally,the use of two ethylene/styrene interpolymers having different styrenecontents provides higher conductivity than the case for which oneethylene/styrene interpolymer is used, at equivalent conductive fillerlevels. The exception is for the comparison to the case of a singleethylene/styrene interpolymer which has a styrene content of greaterthan 75 wt %.

EXAMPLES 51-53

[0281] These Examples show as do the examples of Table 8 that,generally, the use of two ethylene/styrene interpolymers havingdifferent styrene contents provides higher conductivity than the casefor which one ethylene/styrene interpolymer is used, at equivalentconductive filler levels. TABLE 9 First ESI Second ESI#14 ESIConductivity* at Melt Melt 6 wt % Degussa wt % (mol %) Index, wt % in wt% (mol %) Index, wt % in XE2 Ex# styrene G# blend styrene (ESI #) G#blend (S/cm) 51 45.0(18.0) 1.4 94  0 2.3E−8 52 80.0 (51.8) 10.0 947.8E−3 (ESI #17) 53 45.0(18.0) 1.4 75 80.0 (51.8) 10.0 19 3.2E−5(1.5E−3) (ESI #17)

[0282] These results show that when the minor component of the blend hasa styrene content of less than or equal to about 75 wt % styrene then amore than additive increase in conductivity is observed relative to theconductivity's of the individual blend components.

EXAMPLES 54-65

[0283] The Examples in Table 10 illustrate the conductive modificationof ethylene/styrene interpolymers with a different conductive filler, anearly white colored inorganic semiconductor FT-1000 produced by TheNagase Corporation. For these, a larger amount of conductive filler isrequired in order to achieve semiconductivity in comparison to the useof conductive carbons. The results in Table 10 show, similar to those ofTable 9, that the use of two Ethylene/styrene interpolymers havingdifferent styrene contents provides higher conductivity than the casefor which one ethylene/styrene interpolymer is used, at equivalentconductive filler levels. The results also illustrate that severaldifferent types of inorganic semiconducting oxides can be used for thisinvention. These conductive composites are significant because they arewhite in color, in comparison to the black color of conductive carbonmodified polymers. The white color provides easy inspection of a shapedarticle for other contaminants such as dust and other particulates,which is especially desirable in clean room environments. TABLE 10 ESIComponent B (wt %) Component C (wt %) Conduct- Component A wt % (mol %)wt % in wt % (mol %) wt % in ivity* Ex # (wt % in blend) styrene (ESI #)G# blend styrene (ESI #) G# blend S/cm 54 FT-1000(35) 77.0 (47.4) (ESI#20) 1.2 65 — — —  <1E−8 55 FT-1000(35) 80.0 (51.8) (ESI #17) 10.0 65 —— — 3.7E−8 56 FT-1000(35) 22.0 (7.06) (ESI #16) 1.2 52 80.0 (51.8) (ESI#17) 10.0 13 6.0E−8 57 FT-1000(35) 22.0 (7.06) (ESI #16) 1.2 13 80.0(51.8) (ESI #17) 10.0 52 1.5E−7 58 FT-1000(35) 22.0 (7.06) (ESI #16) 1.252 66 (34.3) 11.2 13  <1E−8 59 FT-SN-100D(40) 22.0 (7.06) (ESI #16) 1.212 80.0 (51.8) (ESI #17) 10.0 48 4.1E−6 60 ET-300W(40) 22.0 (7.06) (ESI#16) 1.2 12 80.0 (51.8) (ESI #17) 10.0 48  <1E−8 61 ET-500W(40) 22.0(7.06) (ESI #16) 1.2 12 80.0 (51.8) (ESI #17) 10.0 48  <1E−8 62FT-3000(40) 22.0 (7.06) (ESI #16) 1.2 12 80.0 (51.8) (ESI #17) 10.0 489.0E−8 63 SN-100P(40) 22.0 (7.06) (ESI #16) 1.2 12 80.0 (51.8) (ESI #17)10.0 48 8.6E−6 64 FT-1000(40) 22.0 (7.06) (ESI #16) 1.2 12 80.0 (51.8)(ESI #17) 10.0 48 1.3E−6 65 FT-1000(40) 22.0 (7.06) (ESI #16) 1.2 4880.0 (51.8) (ESI #17) 10.0 12 1.7E−5

EXAMPLES 66

[0284] This Example shows that the use of two or more ethylene/styreneinterpolymers is also advantageous in a rubber modified polypropylene(“TPO”) since their addition results in enhancement of surfaceconductivity in comparison to the formulation having no Ethylene/styreneinterpolymers. TABLE 11 (all blends include Cabot XE-72 carbon black at12 wt %) Polypropylene ESI#21 ESI#17 Conductivity Conductivity (PP44)Polyethylene Rubber wt % (mol %) Wt. wt % (mol %) (core) (surface) Ex #Wt. % Name Wt. % Name Wt. % Styrene G# % Styrene G# Wt. % S/cm S/cm Ex66 52 0 EG 8200 26 22 (7.1) 8 5 80 (51.8) 10 5 1.0E−6   2.6E−8 Comp Ex49 IP-60 6 EG 8200 33 4.9E−6 <1.0E−8 14

[0285] This data shows that when two ethylene/styrene interpolymercomponents are present in a blend with rubber-modified polypropyleneconductivity can be observed at the surface of a injection molded sampleas well as at the core. This allows for improved paint coatingefficiency in automotive components such as bumpers, door panels, mirrorhousing and the like.

We claim;
 1. A blend of polymeric materials comprising (A) of from about1 to about 99.99 weight percent based on the combined weights ofComponents A, B and C of at least one substantially random interpolymer;and wherein said interpolymer; (1) contains of from about 0.5 to about65 mole percent of polymer units derived from; (a) at least one vinyl orvinylidene aromatic monomer, or (b) at least one hindered aliphatic orcycloaliphatic vinyl or vinylidene monomer, or (c) a combination of atleast one vinyl or vinylidene aromatic monomer and at least one hinderedaliphatic or cycloaliphatic vinyl or vinylidene monomer; (2) contains offrom about 35 to about 99.5 mole percent of polymer units derived fromat least one aliphatic α-olefin having from 2 to 20 carbon atoms; (3)has a molecular weight (Mn) greater than about 1,000; (4) has a meltindex (I₂) of from about 0.01 to about 1,000; (5) has a molecular weightdistribution (M_(w)/M_(n)) of from about 1.5 to about 20; and (B) offrom about 99 to about 0.01 weight percent based on the combined weightsof Components A, B, and C of one or more conductive additives and/or oneor more additives with high magnetic permeability; and (C) of from 0 toabout 98.99 weight percent based on the combined weights of ComponentsA, B, and C of one or more polymers other than A.
 2. The blend of claim1 wherein; (i) Component A is present in an amount of from about 5 toabout 97 weight percent based on the combined weights of Components A, Band C; (ii) Component A contains of from about 1 to about 55 molepercent of polymer units derived from; (a) at least one of said vinyl orvinylidene aromatic monomers, Component A(1)(a), represented by thefollowing general formula:

wherein R¹ is selected from the group of radicals consisting of hydrogenand alkyl radicals containing from 1 to about 4 carbon atoms, preferablyhydrogen or methyl; each R² is independently selected from the group ofradicals consisting of hydrogen and alkyl radicals containing from 1 toabout 4 carbon atoms, preferably hydrogen or methyl; Ar is a phenylgroup or a phenyl group substituted with from 1 to 5 substituentsselected from the group consisting of halo, C₁₋₄-alkyl, andC₁₋₄-haloalkyl; and n has a value from zero to about 4; or b) at leastone of said hindered aliphatic or cycloaliphatic vinyl or vinylidenemonomers, Component A(1)(b), represented by the following generalformula:

wherein A¹ is a sterically bulky, aliphatic or cycloaliphaticsubstituent of up to 20 carbons, R¹ is selected from the group ofradicals consisting of hydrogen and alkyl radicals containing from 1 toabout 4 carbon atoms, preferably hydrogen or methyl; each R² isindependently selected from the group of radicals consisting of hydrogenand alkyl radicals containing from 1 to about 4 carbon atoms, preferablyhydrogen or methyl; or alternatively R¹ and A¹ together form a ringsystem; or (c) a combination of at least one of said vinyl or vinylidenearomatic monomer and at least one of said hindered aliphatic orcycloaliphatic vinyl or vinylidene monomer; (iii) Component A containsof from about 45 to about 99 mole percent of polymer units derived fromat least one of said aliphatic α-olefins selected from the groupconsisting of ethylene or a combination of ethylene and at least one ofpropylene, 4-methyl pentene, butene-1, hexene-1, and octene-1; (iv)Component A has a molecular weight (M_(n)) of from about 5,000 to about1,000,000; (v) Component A has a melt index (I₂) of from about 0.1 toabout 100; (vi) Component A has a molecular weight distribution(M_(w)/M_(n)) of from about 1.8 to about 10; (vii) Component B ispresent in an amount of from about 0.5 to about 50 weight percent basedon the combined weights of components A, B and C and one or moreselected from the group consisting of a) conducting carbon black, carbonfibers, graphite, or graphite fibers; b) metals and alloys selected fromthe group consisting of iron, nickel, steel, aluminum, zinc, lead,copper, bronze, brass, tin, zirconium, silver and gold; c) doped andundoped conjugated intrinsically electrically conductive polymersselected from the group consisting of substituted and unsubstitutedpolyanilines, polyacetylenes, polypyrroles, poly(phenylene sulfides),polyindoles, polythiophenes and poly(alkyl) thiophenes, polyphenylenes,polyvinylene/phenylenes, random or block copolymers of acetylenes andthiophenes, anilines and thiophenes, poly(N-methyl)pyrrole,poly(o-ethoxy)aniline, polyethylene dioxythiophene (PEDT), and poly(3-octyl)thiophene; d) semiconductors and conductors selected from thegroup consisting of doped and undoped metal oxides and nitrides selectedfrom the group consisting of tantalum oxide, antimony doped tin oxide,titanium dioxide-coated with antimony doped tin oxide and aluminumnitride; and doped titanium dioxide; e) high magnetic pemeabilityadditives selected from the group consisting of magnetite, ferric oxide(Fe₃O₄), MnZn ferrite, and silver-coated manganese-zinc ferriteparticles; (viii) Component C is present in an amount of from about 2.5to about 94.5 weight percent based on the combined weights of ComponentsA, B and C and one or more selected from the group consisting of styrenehomopolymers and copolymers, alpha-olefin homopolymers andinterpolymers, thermoplastic olefins, styrenic copolymers, elastomers,thermoset polymers, vinyl halide polymers, and engineeringthermoplastics.
 3. The blend of claim 1 wherein; (i) Component A ispresent in an amount of from about 10 to about 94.5 weight percent basedon the combined weights of components A, B and C; (ii) Component Acontains of from about 2 to about 50 mole percent of polymer unitsderived from; a) the group consisting of styrene, α-methyl styrene,ortho-, meta-, and para-methylstyrene, and the ring halogenatedstyrenes, or b) the group consisting of 5-ethylidene-2-norbornene or1-vinylcyclohexene, 3-vinylcyclohexene, and 4-vinylcyclohexene; or c) acombination of at least one of a) and b); (iii) Component A contains offrom about 50 to about 98 mole percent of polymer units derived fromethylene or a combination of ethylene with one or more C₃-C₈ α-olefins;(iv) Component A has a molecular weight (M_(n)) of from about 10,000 toabout 500,000; (v) Component A has a melt index (I₂) of from about 0.5to about 30; (vi) Component A has a molecular weight distribution(M_(w)/M_(n)) of from about 2 to about 5; and (vii) Component B ispresent in an amount of from about 1 to about 25 weight percent based onthe combined weights of Components A, B and C and is selected from thegroup consisting of conducting carbon black, carbon fibers, graphite,graphite fibers, and doped and/or undoped conjugated intrinsicallyelectrically conductive polymers selected from the group consisting ofsubstituted and unsubstituted polyanilines, polyacetylenes,polypyrroles, poly(phenylene sulfides), polyindoles, polythiophenes andpoly(alkyl) thiophenes, polyphenylenes, polyvinylene/phenylenes, randomor block copolymers of acetylenes and thiophenes, anilines andthiophenes, poly(N-methyl)pyrrole, poly(o-ethoxy)aniline, polyethylenedioxythiophene (PEDT), poly (3-octyl)thiophene; indium doped tin oxide,antimony doped tin oxide, and titanium dioxide-coated with antimonydoped tin oxide, magnetite, ferric oxide (Fe₃O₄), MnZn ferrite, andsilver-coated manganese-zinc ferrite particles; and (viii) Component Cis present in an amount of from about 5 to about 89 weight percent basedon the combined weights of Components A, B and C and is one or moreolefin homopolymers and copolymers selected from the group consisting ofpolypropylene, propylene/C₄-C₂₀ α-olefin copolymers, polyethylene, andethylene/C₃-C₂₀ α-olefin copolymers, polyester, nylon, polyphenyleneoxide, polycarbonate.
 4. A blend of claim 3 wherein i) said vinyl orvinylidene aromatic monomer, Component A1(a), is styrene; ii) saidaliphatic α-olefin, Component A2, is ethylene, or a combination ofethylene with one or more C₃-C₈ α-olefins; iii) said conductiveadditive, Component B, is selected from the group consisting ofconducting carbon black, carbon fibers, graphite, and graphite fibers;and iv) said thermoplastic polyolefin, Component C, is selected from thegroup consisting of one or more olefin homopolymers and copolymersselected from the group consisting of polypropylene,polypropylene/C₂-C₂₀ α-olefin copolymers, polyethylene,polyethylene/C₃-C₂₀ α-olefin copolymers, ethyl vinyl acetate (EVA), andrubber-modified polypropylene.
 5. The blend of claim 3 wherein; (i)Component B is a doped and/or undoped conjugated intrinsicallyelectrically conductive polymers selected from the group consisting ofsubstituted and unsubstituted polyanilines, polyacetylenes,polypyrroles, poly(phenylene sulfides), polyindoles, polythiophenes andpoly(alkyl) thiophenes, polyphenylenes, polyvinylene/phenylenes, randomor block copolymers of acetylenes and thiophenes, anilines andthiophenes, poly(N-methyl)pyrrole, poly(o-ethoxy)aniline, polyethylenedioxythiophene (PEDT), and poly (3-octyl)thiophene.
 6. The blend ofclaim 3 wherein; Component B is a magnetic particle selected from thegroup consisting of magnetite, ferric oxide (Fe₃O₄), manganese-zincferrite, and silver-coated manganese-zinc ferrite particles.
 7. Theblend of claim 1 wherein; (i) Component C are homogeneous interpolymershaving a narrow branching distribution and composition distributionprepared using a metallocene catalyst system.
 8. The blend of claim 7wherein; (i) Component C comprises a substantially linear interpolymers.9. A blend of claim 3 wherein i) said vinyl or vinylidene aromaticmonomer, Component A1(a), is styrene; ii) said aliphatic α-olefin,Component A2, is ethylene or a combination of ethylene with one or moreC3-C8 α-olefins iii) said conductive additive, Component B, ispolyaniline.
 10. A blend of claim 3 wherein i) said vinyl or vinylidenearomatic monomer, Component A1(a), is styrene; ii) said aliphaticα-olefin, Component A2, is ethylene or a combination of ethylene withone or more C3-C8 α-olefins; iii) said conductive additive, Component B,is an indium doped tin oxide, antimony doped tin oxide, or titaniumdioxide-coated with antimony doped tin oxide.
 11. A blend of claim 3wherein Component C is selected from the group consisting of one or moreof polyisoprene, polybutadiene, natural rubbers, ethylene/propylenerubbers, ethylene/propylene diene (EPDM) rubbers, styrene/butadienerubbers, and thermoplastic polyurethanes.
 12. A blend of claim 1 furthercomprising; (D) an additive selected from the group consisting of talc,calcium carbonate, alumina trihydrate, glass fibers, marble dust, cementdust, clay, feldspar, silica or glass, fumed silica, alumina, magnesiumoxide, magnesium hydroxide, indium doped tin oxide, antimony oxide, zincoxide, barium sulfate, aluminum silicate, calcium silicate, titaniumdioxide, titanates, glass microspheres, chalk and any combinationthereof.
 13. A blend of claim 1 wherein Component A is a crosslinkedinterpolymer.
 14. A blend of claim 4 wherein Component A is acrosslinked interpolymer.
 15. A blend of claim 5 wherein Component A isa crosslinked interpolymer.
 16. A blend of claim 6 wherein Component Ais a crosslinked interpolymer.
 17. A blend of claim 8 wherein ComponentA is a crosslinked interpolymer.
 18. A blend of claim 9 whereinComponent A is a crosslinked interpolymer.
 19. A blend of claim 10wherein Component A is a crosslinked interpolymer.
 20. A blend of claim11 wherein Component A is a crosslinked interpolymer.
 21. A blend ofclaim 1 wherein in Component B has a magnetic permeability 20 timesgreater than that of copper.
 22. A blend of claim 21 wherein inComponent B has a magnetic permeability 100 times greater than that ofcopper.
 23. An article resulting from injection, compression, extrusion,coextrusion, or blow molding, solution casting, thermoforming, orrotomolding the blend of claim
 1. 24. An article resulting from coatinga substrate with the blend of claim
 1. 25. A sheet, film, multilayeredstructure, prepared from the blend of claim
 1. 26. A wire or cableassembly prepared from the blend of claim
 1. 27. A tire prepared fromthe blend of claim
 1. 28. A flooring system, bench top or counter topprepared from the blend of claim
 1. 29. A conductive foam or fiberprepared from the blend of claim
 1. 30. A conductive foam comprising ablend of polymeric materials comprising (A) of from about 10 to about 90weight percent based on the combined weights of Components A, B and C ofat least one substantially random interpolymer; and wherein saidinterpolymer; (1) contains of from about 0.5 to about 65 mole percent ofpolymer units derived from; (a) at least one vinyl or vinylidenearomatic monomer, or (b) at least one hindered aliphatic orcycloaliphatic vinyl or vinylidene monomer, or (c) a combination of atleast one vinyl or vinylidene aromatic monomer and at least one hinderedaliphatic or cycloaliphatic vinyl or vinylidene monomer; (2) contains offrom about 35 to about 99.5 mole percent of polymer units derived fromat least one aliphatic α-olefin having from 2 to 20 carbon atoms; (3)has a molecular weight distribution (M_(w)/M_(n)) of from about 1.5 toabout 20; and (B) of from about 0.5 to about 50 weight percent based onthe combined weights of Components A, B, and C of one or more conductiveadditives and/or one or more additives with high magnetic permeability;and (C) of from about 10 to about 90 weight percent based on thecombined weights of Components A, B, and C of one or more polymers otherthan A.
 31. The foam of claim 30 wherein a) Component B is present in anamount of from about 1 to about 40 weight percent based on the combinedweights of Components A, B, and is selected from the group consisting ofcarbon black, alkyl amines; quaternary ammonium compounds, LiPF₆, KPF₆,lauryl pyridinium chloride, sodium cetyl sulphate, glycerol esters,sorbitan esters, and ethoxylated amines; and b) Component C; selectedfrom the group consisting of ethylene and/or alpha olefin homopolymersand of ethylene/alpha olefin interpolymers.
 32. The foam of claim 30wherein Component B is present in an amount of from about 0.5 to about 2weight percent based on the combined weights of Components A, B, and Cand Component B is an antistatic additive and wherein Component C isLDPE, a homogeneous ethylene/alpha olefin interpolymer or ethylvinylacetate.
 33. The foam of claim 30 wherein Component B is present in anamount of from about 10 to about 30 weight percent based on the combinedweights of Components A, B, and C and Component B is a conductiveadditive and Component C is LDPE, a homogeneous ethylene/alpha olefininterpolymer or ethylvinyl acetate.
 34. A blend of polymeric materialscomprising (A) from about 1 to about 99.99 weight percent based on thecombined weights of Components A, B and C of at least two substantiallyrandom interpolymers; and (1) wherein more than 50 wt % of saidinterpolymers (a) contains from about 0.5 to about 65 mole percent ofpolymer units derived from; (i) at least one vinyl or vinylidenearomatic monomer, or (ii) at least one hindered aliphatic orcycloaliphatic vinyl or vinylidene monomer, or (iii) a combination of atleast one vinyl or vinylidene aromatic monomer and at least one hinderedaliphatic or cycloaliphatic vinylidene monomer; (b) contains of fromabout 35 to about 99.5 mole percent of polymer units derived from atleast one aliphatic α-olefin having from 2 to 20 carbon atoms; and (2)wherein less than 50 wt % of said interpolymers contains (a) of fromabout 0.5 to about 45 mole percent of polymer units derived from; (i) atleast one vinyl or vinylidene aromatic monomer, or (ii) at least onehindered aliphatic or cycloaliphatic vinyl or vinylidene monomer, or(iii) a combination of at least one vinyl or vinylidene aromatic monomerand at least one hindered aliphatic or cycloaliphatic vinylidenemonomer; (b) contains of from about 55 to about 99.5 mole percent ofpolymer units derived from at least one aliphatic α-olefin having from 2to 20 carbon atoms; and (B) from about 99 to about 0.01 weight percentbased on the combined weights of Components A, B, and C of one or moreconductive additives and/or one or more additives with high magneticpermeability; and (C) from 0 to about 98.99 weight percent based on thecombined weights of Components A, B, and C of one or more polymers otherthan those of A.
 35. A blend of claim 34 wherein i) said vinylidenearomatic monomer, Component A1(a), is styrene; ii) said aliphaticα-olefin, Component A2, is ethylene or a combination of ethylene withone or more C3-C8 α-olefins; iii) said conductive additive, Component B,is an conducting carbon black, polyaniline, indium doped tin oxide,antimony doped tin oxide, titanium dioxide-coated with antimony dopedtin oxide.
 36. The blend of claim 34 wherein Component C is a rubbermodified polypropylene.
 37. A latex comprising the blend of claim
 1. 38.A latex comprising the blend of claim 34.